Polaris Offroad Vehicle 600 IQ Racer User Manual

Download from Www.Somanuals.com. All Manuals Search And Download.  
WARNING  
Read, understand, and follow all of the  
instructions and safety precautions in  
this manual and on all product labels.  
Failure to follow the safety precautions  
could result in serious injury or death.  
WARNING  
The engine exhaust from this product  
contains chemicals known to the State  
of California to cause cancer, birth  
defects or other reproductive harm.  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WELCOME  
Thank you for purchasing a Polaris vehicle, and welcome to our  
world-wide family of Polaris owners. We proudly produce an exciting  
line of utility and recreational products.  
S Snowmobiles  
S All-terrain vehicles (ATVs)  
S RANGER utility vehicles  
S Victory motorcycles  
We believe Polaris sets a standard of excellence for all utility and  
recreational vehicles manufactured in the world today. Many years of  
experience have gone into the engineering, design, and development of  
your Polaris vehicle, making it the finest machine we’ve ever  
produced.  
For safe and enjoyable operation of your vehicle, be sure to follow the  
instructions and recommendations in this owner’s manual. Your  
manual contains instructions for minor maintenance, but information  
about major repairs is outlined in the 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  
service needs during, and after, the warranty period.  
We also take great pride in our complete line of apparel, parts and  
accessories, available through our online store at  
www.purepolaris.com. Have your accessories and clothing delivered  
right to your door!  
1
Download from Www.Somanuals.com. All Manuals Search And Download.  
POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris  
Industries Inc.  
Copyright 2007 Polaris Sales Inc. All information contained within this publication is  
based on the latest product information at the time of publication. Due to constant  
improvements in the design and quality of production components, some minor  
discrepancies may result between the actual vehicle and the information presented in this  
publication. Depictions and/or procedures in this publication are intended for reference  
use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or  
reuse of the depictions and/or procedures contained within, whether whole or in part, is  
expressly prohibited.  
Printed in U.S.A.  
2008 600 IQ Racer/600RR Owner’s Manual P/N 9921089  
2
Download from Www.Somanuals.com. All Manuals Search And Download.  
TABLE OF CONTENTS  
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4  
This section contains helpful information for owners and drivers and  
illustrates the location of important identification numbers that should  
be recorded in the owner’s manual.  
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7  
This section describes safe vehicle operation and identifies warning  
decals and their locations.  
Features and Controls . . . . . . . . . . . . . . . . . . . . . 24  
This section illustrates the locations of your snowmobile’s controls and  
features.  
The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30  
This section explains how to tailor the suspension and other features  
for an optimum riding experience.  
Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . . . 44  
This section explains procedures that must be performed before riding.  
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50  
This section explains proper engine break-in, operation of features and  
operating procedures.  
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59  
This section defines your role, and your dealer’s role, in your  
snowmobile’s regular maintenance.  
Polaris Products . . . . . . . . . . . . . . . . . . . . . . . . . . 99  
Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . 100  
This section is a quick reference guide to solving problems.  
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 105  
Maintenance Record . . . . . . . . . . . . . . . . . . . . . . 112  
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 115  
3
Download from Www.Somanuals.com. All Manuals Search And Download.  
INTRODUCTION  
Important Notes for Owners and Drivers  
After reading this manual, store it in the snowmobile for convenient  
reference. It should remain with the snowmobile when the snowmobile  
is sold.  
When teaching inexperienced operators to ride, set up a predetermined  
course for practice. Make sure they know how to drive and control the  
snowmobile before allowing them to make longer trips. Teach them  
proper snowmobile courtesy, and enroll them in driver’s training and  
safety courses sponsored by local or state organizations.  
Follow the maintenance program outlined in this manual. Preventive  
maintenance ensures that critical components of the snowmobile are  
inspected by your dealer at specific mileage intervals.  
You and your dealer must complete the registration form included with  
your snowmobile and forward it to us. This completed form is  
necessary to ensure warranty coverage.  
Protect and preserve your right to ride by joining your local trail riding  
clubs.  
4
Download from Www.Somanuals.com. All Manuals Search And Download.  
INTRODUCTION  
Preservation of the Environment  
Polaris is committed to supporting an environmental education  
campaign. We encourage governments to adopt rigorous safety training  
programs that encourage protection of our environment, including  
wildlife and vegetation.  
Snowmobile clubs and other organizations are working together to  
protect our environment. Please support their efforts and operate your  
snowmobile with consideration for the protection and preservation of  
our environment.  
Noise Level  
One of the most publicized issues about snowmobiles is noise. The  
Society of Automotive Engineers (SAE), the standard-setting body for  
snowmobile development, recommends that snowmobiles conform to  
prescribed sound levels.  
Polaris snowmobiles are engineered to conform to these SAE  
standards. Our muffler systems are designed to reduce noise levels and  
must not be altered or removed. The sound of your snowmobile may  
not be welcome to non-snowmobilers, so you have a responsibility to  
operate your snowmobile with concern for others. We do our part by  
manufacturing quieter machines; we ask your help to further reduce the  
impact of noise by operating your snowmobile safely and responsibly.  
Air Pollution  
Polaris engineers continuously investigate ways to reduce emission  
levels of two-stroke engines. We expect our efforts to lead to the  
reduction of potential air pollution.  
In addition to our technological research, we encourage government  
agencies, manufacturers, distributors, dealers, ecologists, and other  
interested parties to work together to develop data on environmental  
topics.  
5
Download from Www.Somanuals.com. All Manuals Search And Download.  
INTRODUCTION  
Vehicle Identification Numbers  
Record your snowmobile’s identification numbers in the spaces  
provided.  
Vehicle Model Number:  
Tunnel VIN:  
(lower right side of the tunnel)  
Engine Serial Number:  
(right front side of engine crankcase)  
6
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
The following signal words and symbols appear throughout this  
manual and on your vehicle. Your safety is involved when these words  
and symbols are used. Become familiar with their meanings before  
reading the manual.  
The safety alert symbol, on your vehicle or in this manual, alerts you to  
the potential for injury.  
WARNING  
The safety alert warning indicates a potential hazard that may result in  
serious injury or death.  
CAUTION  
The safety alert caution indicates a potential hazard that may result in  
minor injury or damage to the vehicle.  
CAUTION  
A caution indicates a situation that may result in damage to the vehicle.  
NOTE:  
A note will alert you to important information or instructions.  
7
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Follow the recommended maintenance program outlined beginning on  
page 60 of this manual to ensure that all critical components on the  
snowmobile are thoroughly inspected by your dealer at specific  
mileage intervals.  
WARNING  
Driving a snowmobile requires your full attention. DO NOT drink alcohol  
or use drugs or medications before or while driving or riding as a  
passenger. They will reduce your alertness and slow your reaction time.  
Snowmobiles are capable of traveling at high speeds. Use extra caution  
to ensure operator safety. Make sure your snowmobile is in excellent  
operating condition at all times. Always check major and vital safety  
components before every ride.  
All Polaris snowmobiles are designed and tested to provide safe  
operation when used as directed. Failure of critical machine components  
may result from operation with any modifications, especially those that  
increase speed or power. DO NOT MODIFY YOUR MACHINE. The  
snowmobile may become aerodynamically unstable at speeds higher  
than those for which it is designed. Loss of control may occur at higher  
speeds. Modifications may also create a safety hazard and lead to bodily  
injury.  
The warranty on your entire machine is terminated if any equipment  
has been added, or any modifications have been made, to increase the  
speed or power of the snowmobile.  
8
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Riding Apparel  
Be prepared, be warm and be  
comfortable when riding. Be  
aware of the weather  
forecast, especially the  
windchill, and dress  
accordingly. See the chart  
on page 19.  
WARNING  
Avoid wearing loose  
clothing or long scarves,  
which can become  
entangled in moving parts  
and cause serious injury.  
Always wear an approved  
helmet and eye  
protection.  
Helmet  
Wearing a helmet can prevent a severe head injury. Whenever riding a  
Polaris vehicle, always wear a helmet that meets or exceeds established  
safety standards.  
Approved helmets in the USA and Canada bear a U.S. Department of  
Transportation (DOT) label.  
Approved helmets in Europe, Asia and  
Oceania bear the ECE 22.05 label. The  
ECE mark consists of a circle surrounding  
4
E
the letter E, followed by the distinguishing  
number of the country which has granted  
051039  
approval. The approval number and serial  
0006.031  
number will also be displayed on the label.  
Eye Protection  
Do not depend on eyeglasses or sunglasses for eye protection.  
Whenever riding a Polaris vehicle, always wear shatterproof goggles or  
use a shatterproof 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.  
9
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Stay Clear of Track  
Your snowmobile is propelled by a revolving track that must be  
partially exposed for proper operation.  
WARNING  
Serious injuries may result if hands, feet, or  
clothing become entangled in the track. Be  
alert when riding, and remain properly seated to  
stay clear of the track.  
Never hold the snowmobile up or stand  
behind it while warming up the track. A  
loose track or flying debris could cause  
serious injury or death. We recommend  
having your dealer perform all track  
service and alignment procedures.  
Stay Clear of Engine  
Never attempt adjustments with the engine running. Stop the engine,  
raise the hood, make the adjustment, secure shields and guards, secure  
the hood, and then restart the engine to check its operation.  
WARNING  
Serious injury can occur if fingers or clothing contact the moving parts of  
an engine. Always stop the engine before attempting adjustments.  
Riding Position  
Operating a snowmobile requires skill and balance for proper control.  
Rider positions may vary with experience; but under most conditions,  
the proper position is to be seated with both feet on the running boards  
and both hands on the handlebar grips for proper throttle, brake and  
steering control.  
WARNING  
Improper riding position may reduce control and could result in serious  
injury or death. Always be properly seated and in position to control your  
vehicle.  
10  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Driver Awareness  
Slow down when traveling near poles,  
posts, or other obstacles. Be especially  
alert if you’re snowmobiling after dark.  
Always be on the alert for wire fences.  
Single strands are especially dangerous,  
since there may be a great distance  
between posts. Guy wires on utility poles  
are also difficult to distinguish.  
Make sure the way is clear before crossing  
railroads and other roads and highways.  
The noise of your machine will drown out  
the sound of approaching vehicles. Look  
ahead, behind, and to both sides before  
turning or crossing railroad tracks or  
highways. Steep embankments may also  
hide your view. Always leave yourself a  
way out.  
Variances in snow depth and/or water  
currents may result in uneven ice  
thickness. Always check with local  
residents or authorities for general information on conditions when  
traveling on lakes and streams that are strange to you. Before riding  
your machine on a frozen body of water, be sure the ice is thick enough  
to support the machine and its operator, as well as the force created by  
a moving vehicle. You may drown if you and the snowmobile break  
through the ice.  
When teaching inexperienced operators to ride, set up a predetermined  
course for practice. Make sure they know how to drive and control the  
snowmobile before allowing them to make longer trips. Teach them  
proper snowmobile courtesy, and enroll them in driver’s training and  
safety courses sponsored by local or state organizations.  
11  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Disabled Operators  
Safe operation of this rider-active vehicle requires good judgement and  
physical skills. Operators with cognitive or physical disabilities have  
an increased risk of loss of control, which could result in serious injury  
or death.  
Rider Capacity  
Your Polaris snowmobile is designed for a single rider only. Do not  
carry a passenger.  
Survival Preparation  
For your safety, always ride in a group of other snowmobilers. Always  
tell someone where you’re going and how long you expect to be gone.  
If it isn’t possible to ride with others, and you must travel into remote  
areas, always carry survival equipment that’s appropriate to the  
conditions you may encounter. Such equipment may include, but is  
not limited to: extra clothing, a sleeping bag, a flashlight, food and  
water, a signaling mirror, a means of building a fire, and a two-way  
radio or cellular telephone.  
For added protection, carry the following items on your snowmobile at  
all times:  
SSpare Drive Belt  
STow Rope  
SFuel Deicer  
STrail Map  
SFirst Aid Kit  
SExtra Set of Spark Plugs  
SExtra Oil  
SWinter Survival Kit  
SOwner’s Manual  
12  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Avalanches  
Snowmobilers should always be properly  
trained and equipped before traveling in  
mountainous terrain:  
S Take an avalanche class  
S Travel with experienced people  
S Travel on designated trails  
S Make sure each person is equipped with  
a shovel, probe and avalanche beacon.  
You don’t have to be snowmobiling on a slope for an avalanche to  
occur. Be aware that all of the snow is connected. You may be riding  
on a flat slope or snow covered road, but if the snowpack above is  
unstable enough you can trigger an avalanche on a steeper slope above  
you. Always be aware of snow conditions above you as you travel in  
mountainous terrain.  
Before riding in mountainous terrain, call or log on to your local  
avalanche advisory to get current weather and snow stability  
information.  
For more information about avalanche training and avalanche  
conditions, contact local law enforcement in your area, or visit the  
American and Canadian online avalanche centers at  
www.avalanche.org.  
Ice and Snow Build-up  
WARNING  
Ice and snow build-up may interfere with the steering of your machine,  
resulting in serious injury or death. Keep the underhood area free of  
snow and ice.  
Before driving, manually turn the skis to the left and right to be sure  
ice and snow are not interfering with full left and right steering. If  
difficulty is encountered, remove ice and snow build-up that may be  
obstructing the steering linkage.  
13  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Excessive Speed  
WARNING  
High speed driving, especially at night, could result in serious injury or  
death. Always reduce speed when driving at night or in inclement  
weather.  
Always observe all laws governing snowmobile operation and speed  
limits. Always be alert and pay attention to the trail ahead. Multiplying  
speed (MPH) by 1.5 will equal the approximate number of feet per  
second your machine travels. If your speed is 40 MPH, your machine  
is traveling about 60 feet per second. If you look back for only two  
seconds, your machine will travel about 120 feet. If your speed is 60  
MPH, your machine will travel about 180 feet in two seconds.  
Traveling at night requires extra caution. Check headlight and taillight  
to ensure proper operation, and don’t over-drive your headlight beam.  
Always be able to bring your machine to a stop in the distance  
illuminated by the headlight.  
Driving on Slippery Surfaces  
WARNING  
Never attempt an abrupt change of direction when operating on  
slippery surfaces. Proceed slowly and use extra caution.  
Driving on ice or hard-packed snow reduces steering and braking control,  
which may result in loss of control and serious injury or death. Slow  
down and use extra caution when operating on slippery surfaces.  
Driving Downhill  
When riding downhill, shift your weight to the rear of the machine and  
reduce your speed to a minimum. Apply just enough throttle to keep  
the clutch engaged, allowing the engine’s compression to help slow the  
machine and keep it from rolling freely 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.  
14  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Driving in Hilly Terrain  
WARNING  
Climbing a hill or crossing the face of a slope may result in loss of  
balance and machine roll-over, causing serious injury or death. Use  
caution and good judgement when driving in hilly terrain.  
Use extra caution when operating in hilly terrain. If climbing a hill is  
unavoidable, keep your weight low and forward. If you must cross the  
face of a slope, keep your weight on the uphill side of the machine to  
maintain proper balance and avoid possible roll-over.  
Slow down when reaching the crest of a hill. Be prepared to react to  
obstacles, sharp drops or other people or vehicles that may be on the  
other side of the hill.  
If you’re unable to continue up a hill, turn the machine downhill before  
it loses momentum. If this isn’t possible, spin the track just enough to  
dig in to prevent it from rolling back down the hill. Stop the engine  
and set the parking brake (if equipped). Keeping away from the  
downhill side of the machine, pull the rear of the snowmobile around  
and point the front end and skis downhill. Remount the machine,  
restart the engine, release the parking brake, and descend the hill  
carefully.  
15  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Drive Belt  
Do not operate the engine with the drive belt removed.  
Any servicing that requires operation without a belt must be performed  
by your dealer. Operation of the engine with the belt removed may  
result in injury or damage to the engine.  
Intake Silencer  
Do not operate the engine with the intake silencer or filter removed.  
Damage to the engine may occur if the intake silencer or filter are  
removed.  
Clutches  
Do not attempt to service the clutches.  
All clutch service must be performed by your dealer. The clutch is a  
complex mechanism that rotates at high speeds. Each clutch is  
dynamically balanced before installation. Any tampering may disrupt  
this precision balancing and create an unstable condition.  
Cold Weather Drive-Away  
Whenever your snowmobile has been parked for a length of time,  
especially overnight, always make sure the skis and track are loosened  
from ice and snow before attempting to drive. Apply the throttle with  
enough authority to put the machine into motion, but always operate  
within safety limits.  
Maneuverability  
While much control and maneuverability is achieved through the  
steering system and skis, maximum control is achieved by the shifting  
of your body weight. Maneuverability will change for lighter operators  
or machines designed to carry a load.  
16  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Inadequate Snow Conditions  
WARNING  
Do not drive for prolonged periods on blacktop, gravel, or ice. Doing so  
could cause irreversible track damage and lead to serious injury.  
Since snow provides the only lubrication for the power slide  
suspension and, on liquid cooled models, cooling for the engine,  
adequate snow cover is a requirement for operation of your machine.  
Driving in too little snow will result in excessive wear and damage to  
the slide rail, track and/or engine.  
If the machine becomes stuck in snow, clear the running board area of  
snow, then step down the snow in front of the machine so that when  
the throttle is opened, the snowmobile will be able to climb up and  
over the snow.  
CAUTION  
When operating on icy surfaces or hard-packed snow, avoid overheating  
the slide rail and track. Lack of lubrication and cooling will cause  
overheating of the slide rail and track, resulting in premature wear and  
failure. If frequently operating in low cooling conditions, see your dealer  
for an optional wheel kit that will reduce the wear from overheating.  
17  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Driving Responsibly  
Every snowmobile handles differently, and even the most docile  
conditions may become dangerous if operators drive improperly. If  
you’re new to snowmobiling, acquaint yourself with the machine and  
with what it will and won’t do under various conditions. Even  
seasoned drivers should spend some time getting the feel for a machine  
before attempting ambitious maneuvers.  
S A snowmobile depends on the rider’s body position for proper bal-  
ance in executing turns, traversing hills, etc. Always start on a  
smooth, level area to begin building your operating experience.  
S Before allowing someone else to use your snowmobile, know the  
extent of their operating skills. Check to see if they’ve taken a  
snowmobile safety course and have an operator’s certificate. For  
their protection, as well as yours, make sure they take a snowmobile  
safety course. Everyone can benefit from the course.  
S Don’t “jump” your snowmobile over large drifts or similar terrain.  
Jumping may injure your back because of spinal compression that  
could occur when the snowmobile impacts the ground. The seat and  
suspension of your snowmobile have been designed to provide  
protection under normal riding conditions. Your snowmobile is not  
intended for this kind of use.  
S Be courteous to oncoming traffic by dimming your headlights and  
reducing your speed.  
S When traveling in a group of snowmobiles, don’t tailgate (follow too  
closely). Leave enough distance between snowmobiles to provide  
ample stopping room and to provide protection from flying snow  
and debris. Allow even more distance when driving on slippery sur-  
faces or when driving in darkness or other low visibility conditions.  
Be aware of any snowmobile traffic around your vehicle. Drive de-  
fensively to avoid accidents.  
18  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Operator Safety  
Windchill/Temperature Charts  
The following information is provided to help you determine when  
temperatures become dangerous for riding.  
WIND CHILL CHART (°F)  
Wind  
Speed  
in  
Actual Thermometer Reading (°F)  
MPH  
40 35 30 25 20 15 10  
5
0
-5 -10 -15 -20 -25 -30 -35 -40 -45  
Equivalent Temperature (°F)  
-5 -10 -15 -20 -25 -30 -35 -40 -45  
-5 -11 -16 -22 -28 -34 -40 -46 -52 -57 -63  
Calm 40 35 30 25 20 15 10  
5
0
5
36 31 25 19 13  
7
3
1
10  
15  
20  
25  
30  
35  
40  
45  
50  
55  
60  
34 27 21 15  
32 25 19 13  
30 24 17 11  
9
6
-4 -10 -16 -22 -28 -35 -41 -47 -53 -59 -66 -72  
-7 -13 -19 -26 -32 -39 -45 -51 -58 -64 -71 -77  
-9 -15 -22 -29 -35 -42 -48 -55 -61 -68 -74 -81  
0
4
-2  
29 23 16  
28 22 15  
28 21 14  
27 20 13  
26 19 12  
26 19 12  
25 18 11  
25 17 10  
9
8
7
6
5
4
4
3
3
1
0
-1  
-2  
-4 -11 -17 -24 -31 -37 -44 -51 -58 -64 -71 -78 -84  
-5 -12 -19 -26 -33 -39 -46 -53 -60 -67 -73 -80 -87  
-7 -14 -21 -27 -34 -41 -48 -55 -62 -69 -76 -82 -89  
-8 -15 -22 -29 -36 -43 -50 -57 -64 -71 -78 -84 -91  
-9 -16 -23 -30 -37 -44 -51 -58 -65 -72 -79 -86 -93  
-3 -10 -17 -24 -31 -38 -45 -52 -60 -67 -74 -81 -88 -95  
-3 -11 -18 -25 -32 -39 -46 -54 -61 -68 -75 -82 -89 -97  
-4 -11 -19 -26 -33 -40 -48 -55 -62 -69 -76 -84 -91 -98  
Frostbite in >>  
30 min.  
10 min.  
5 min.  
WIND CHILL CHART (°C)  
Wind  
Speed  
in  
Actual Thermometer Reading (°C)  
KPH  
5
2
-1  
-4  
-7 -10 -13 -16 -19 -22 -25 -28 -31 -34 -37 -40 -43 -46  
Equivalent Temperature (°C)  
Calm  
8
5
3
2
1
0
2
0
-1  
-
-4  
-7 -10 -13 -16 -19 -22 -25 -28 -31 -34 -37 -40 -43 -46  
-7 -11 -14 -18 -22 -25 -29 -32 -36 -39 -43 -46 -50 -53 -57  
16  
24  
32  
40  
48  
56  
64  
72  
80  
88  
96  
-2 -6 -10 -13 -17 -21 -24 -28 -32 -36 -39 -43 -47 -50 -54 -58 -62  
-3 -7 -11 -15 -19 -22 -26 -30 -34 -38 -42 -45 -49 -53 -57 -61 -65  
-4 -8 -12 -16 -20 -24 -28 -32 -36 -39 -43 -47 -51 -55 -59 -63 -67  
-1 -5 -9 -13 -17 -21 -25 -29 -33 -37 -41 -45 -49 -53 -57 -61 -65 -69  
-1 -5 -9 -13 -18 -22 -26 -30 -34 -38 -42 -46 -50 -54 -58 -62 -66 -70  
-2 -6 -10 -14 -18 -22 -26 -31 -35 -39 -43 -47 -51 -55 -59 -64 -68 -72  
-2 -6 -10 -15 -19 -23 -27 -31 -35 -40 -44 -48 -52 -56 -61 -65 -69 -73  
-2 -7 -11 -15 -19 -23 -28 -32 -36 -40 -45 -49 -53 -57 -61 -66 -70 -74  
-3 -7 -11 -15 -20 -24 -28 -33 -37 -41 -45 -50 -54 -58 -62 -67 -71 -75  
-3 -7 -12 -16 -20 -24 -29 -33 -37 -42 -46 -50 -55 -59 -63 -67 -72 -76  
-3 -8 -12 -16 -21 -25 -29 -34 -38 -42 -47 -51 -55 -60 -64 -68 -73 -77  
Frostbite in >>  
30 min.  
10 min.  
5 min.  
19  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Safety Decals and Locations  
Warning decals have been placed on the snowmobile for your  
protection. Read and follow the instructions of the decals on the  
snowmobile carefully. If any of the decals depicted in this manual  
differ from the decals on your snowmobile, always read and follow the  
instructions of the decals on the snowmobile.  
If any decal becomes illegible or comes off, contact your Polaris dealer  
to purchase a replacement. Replacement safety decals are provided by  
Polaris at no charge. The part number is printed on the decal.  
Clutch Cover Warning  
This warning decal is found under the hood on the clutch cover:  
WARNING  
AVERTISSEMENT  
Pressure Cap Warning  
This warning decal is found on the coolant  
bottle cover of liquid cooled models.  
Reverse Warning (if equipped)  
The reverse warning decal is located on the  
console, either beside the steering post or below the windshield (on  
equipped models):  
WARNING  
Reverse operation, even at low speeds, can cause loss of control  
resulting in serious injury or death. To avoid loss of control, always:  
Look behind before and while backing up. Avoid sharp turns. Shift to or  
from reverse only when stopped. Apply throttle slowly.  
NOTE: For more information, see Owner’s Manual.  
If electric reverse:  
Machine stopped and engine at idle, push red button on LH control to  
reverse. Flashing light on dash indicates reverse operation. Push button  
again to return to forward.  
20  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Safety Decals and Locations  
Track Warning  
The track warning decal is located on the rear of the tunnel:  
+
Passenger Warning  
This snowmobile is designed for one operator only. A “No Passenger”  
warning decal is located on the lower console:  
+
21  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Safety Decals and Locations  
Operation Warning  
+
22  
Download from Www.Somanuals.com. All Manuals Search And Download.  
SAFETY  
Safety Decals and Locations  
Operation Warning  
23  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES AND CONTROLS  
3
4
2
5
1
13  
6
7
8
12  
9
1. Brake Lever  
2. Oil Light (600RR only)  
3. Tachometer  
14  
4. Temperature Light  
5. Engine Stop Switch  
6. Throttle Control  
10  
7. Choke Control  
8. Recoil Starter Handle  
9. Fuel Filler Cap  
11  
10. Park Brake Lock  
11. Headlight Dimmer Switch  
12. Handlebar Grip Warmer/  
Thumbwarmer Switch  
13. Tether Switch  
15  
14. Master Cylinder  
15. Dragont Ignition System Switch (600 IQ Racer)  
or Electronic Reverse Button (600RR)  
24  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES AND CONTROLS  
1
2
3
11  
10  
4
5
9
8
7
6
1. Handlebar  
2. Windshield  
3. Headlight  
4. Hood  
5. Nosepan  
6. Skis  
7. Track  
8. Suspension  
9. Snow Flap  
10. Taillights  
11. Seat  
25  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES AND CONTROLS  
Polaris DRAGON Ignition System (600 IQ Racer)  
Your snowmobile is equipped with an ignition system feature that  
improves competition performance by increasing exhaust system  
temperature. The DRAGON Ignition System provides maximum  
“holeshot” performance for racing applications.  
WARNING  
DRAGON mode increases the exhaust system temperature and causes  
engine misfire and backfire. Flammable materials and vapors may ignite  
and result in fire and explosion, which may cause serious injury, death or  
property damage. Read the Owner’s Manual. Always follow all  
instructions and warnings.  
DRAGON Mode Facts  
S The DRAGON Ignition System is intended for competition use on  
closed courses by experienced riders only.  
S There is no benefit to using DRAGON mode for normal trail riding.  
S Unnecessary, extended or excessive use of DRAGON mode can re-  
sult in severe engine damage, which is excluded from Polaris war-  
ranty coverage.  
S DRAGON mode usually heats up the exhaust system within 5 to 20  
seconds, depending upon the initial temperature of the exhaust sys-  
tem.  
S Two different sounds may be heard when using DRAGON mode.  
One sound is an erratic misfire that may be heard when the exhaust  
system is heating up. The other sound is a consistent misfire (with a  
slight rise in engine RPM) when the exhaust system is at target oper-  
ating temperature.  
S DRAGON mode maintains the engine speed between 4500 and 5100  
RPM.  
S Be sure that the clutch engages at 5300 RPM or above to prevent  
forward creep of the vehicle. See your dealer if the clutch needs ad-  
justment.  
S Please refer to the Polaris jetting chart and use the recommended jet  
for current temperatures as this system is sensitive to jet changes.  
26  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES AND CONTROLS  
Polaris DRAGON Ignition System (600 IQ Racer)  
DRAGON Mode Operation  
1. Warm up the engine and  
track. See page 54.  
2. When staged at the starting  
line, depress and hold the  
DRAGON button on the left  
handlebar (1).  
3. Slowly advance the throttle  
to the wide-open position  
while keeping the button  
depressed.  
4. Release the button when the  
start flag drops.  
1
NOTE:  
The vehicle will launch  
forward at wide-open  
throttle.  
27  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES AND CONTROLS  
Electronic Reverse (PERCt) (600RR)  
Electronic reverse will activate only if the engine RPM is below 4000.  
If your machine is running at an altitude of over 6000 feet, adjust the  
ignition setting as described below. Always make sure the vehicle is  
stopped and the engine is running at idle before shifting to reverse.  
WARNING  
Improper reverse operation, even at low speeds, may cause loss of  
control, resulting in serious injury or death. Damage will occur to the  
chaincase or transmission if shifting is attempted when the engine is  
operating above idle speed.  
Shift to or from reverse only when the snowmobile is stopped and when  
engine speed is at idle. Look behind the vehicle before and while  
backing. Avoid sharp turns. Apply throttle slowly.  
Engaging Reverse  
1. Stop the snowmobile and  
leave the engine idling.  
2. Make sure the area behind  
your vehicle is clear.  
3. Push the reverse button (1)  
on the left-hand control for  
one second, then release. The  
engine will automatically  
reduce RPM and start a  
reverse rotation. A flashing  
reverse light on the  
tachometer will indicate that  
the transmission is in  
reverse.  
1
4. Apply the throttle slowly to  
make sure the transmission is  
in reverse.  
NOTE:  
The maximum engine RPM will be 6000 when in reverse.  
NOTE:  
If the engine stops running, the snowmobile will be in forward gear  
when it’s restarted.  
28  
Download from Www.Somanuals.com. All Manuals Search And Download.  
FEATURES AND CONTROLS  
Electronic Reverse (PERCt) (600RR)  
Disengaging Reverse  
1. Stop the snowmobile and leave the engine idling.  
2. Push the reverse button for one second and release. The engine will  
slow and begin to rotate forward. The light on the tachometer will  
shut off.  
3. Apply the throttle slowly to make sure the transmission is in  
forward.  
Altitude Setting  
At higher altitudes (above 6000 feet), the engine will require a different  
ignition setting to improve the success of the reverse system. To set for  
a higher altitude, start the engine and hold the button down until the  
light on the tachometer flashes rapidly, then release the button.  
To set the reverse for lower elevations, continue holding the button  
down until the reverse indicator light blinks slowly. Once set, it’s  
stored in memory until changed, whether the engine is running or not.  
Reverse Kit Maintenance  
If your snowmobile is equipped with reverse, or if you have a reverse  
kit installed, it’s especially important to maintain track tension as  
specified on page 88.  
WARNING  
Improper track tension can cause serious damage to the snowmobile,  
which can result in loss of vehicle control and serious injury or death.  
Always maintain the track tension as specified.  
29  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
IQ Front Suspension Adjustments  
Independent Front Suspension (IFS)  
Break in the suspension for about 150 miles (240 km) before making  
any fine-tuning adjustments.  
Settings will vary from rider to rider, depending on rider weight,  
vehicle speed, riding style, and trail conditions. We recommend  
starting with factory settings and then customizing each adjustment  
individually to suit rider preference. The machine should be  
methodically tested, one change at a time, under the same conditions  
(trail and snow conditions, vehicle speed, riding position, etc.) after  
each adjustment until the best ride is achieved.  
IFS Components  
1. Skis  
2. Spindles  
3. Front shocks and springs  
4. Control arms  
IFS Adjustment Options  
S Front shock spring preload  
S Compression damping (see  
page 32)  
2
S Optional springs  
S Optional shock valving (if  
equipped with Walker/Evans  
shocks)  
4
3
S Toe (ski alignment) (see page  
92)  
1
30  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
IQ Front Suspension Adjustments  
WARNING  
Always verify ski alignment before making adjustments to the IFS. See  
page 92 to check alignment. If the skis are misaligned, see your dealer,  
as the camber adjustment may also be affected.  
The tension at which the shock coil spring is set is called spring  
preload. For the best ride, the spring preload should be set as low as  
possible to use the full travel of the ski shock, with occasional light  
bottoming. To determine if your machine is using full travel of the ski  
shock, push the o-ring travel indicator down as far as it will go on the  
shock rod and test ride the machine. The o-ring will move up on the  
rod in direct relation to the amount of travel. If the shock travel is full,  
the bumper will be seated at the top of the shock.  
Shock Absorber Components  
1. Retainer  
2. Shock Rod  
3. O-Ring Travel Indicator  
4. Body  
5. Threaded Spring Preload Adjuster Nut  
6. Reservoir  
4
5
1
3
2
6
31  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
IQ Front Suspension Adjustments  
Front Shock Spring Preload  
Increasing spring preload will increase  
ski-to-ground pressure. Decreasing spring  
B
A
preload will decrease ski-to-ground  
pressure. When adjusting, be sure the  
springs on both the left and right sides of  
the machine are at the same adjustment.  
A = Low preload  
B = High preload  
Increasing the spring preload too much  
may adversely affect the handling of the  
snowmobile and the performance of the  
rear suspension.  
Decreasing the spring preload too much  
may allow the upper spring retainer to fall  
off.  
NOTE:  
Always leave at least one thread  
showing above the nut.  
1. Grasp the spring and turn it to the left to increase preload.  
2. Turn the spring to the right to decrease preload.  
Shock Damping (Walker/Evans Shock)  
1
Turn the adjuster (1) clockwise to  
increase stiffness. Turn the adjuster  
counterclockwise to decrease stiffness.  
32  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
IQ Front Suspension Adjustments  
Shock Valving  
Walker/Evans shocks can be revalved if spring preload alone isn’t  
sufficient and further adjustment is desired to control suspension  
stiffness.  
WARNING  
Changing shock valving on Walker/Evans shocks requires special tools  
and a sound knowledge of mechanical theory, tool use, and shop  
procedures to perform the work safely and correctly. Shocks contain  
high-pressure nitrogen gas. Use extreme caution when handling  
high-pressure service equipment. We recommend that this work be  
performed by a Polaris dealer.  
Front Springs  
For models without externally adjustable or revalvable shocks, the  
front springs can be changed if spring preload alone isn’t sufficient and  
further adjustment is desired to control suspension stiffness. See your  
Polaris dealer for more information.  
33  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
Rear Suspension Adjustments  
Rider weight, riding style, trail conditions, and vehicle speed all affect  
suspension action.  
Each rear suspension can be adjusted to suit rider preference and  
deliver excellent performance for a given set of conditions. However,  
all suspension designs and adjustments involve a compromise, or  
trade-off. For example, a suspension set up for snow-cross racing  
would provide a very stiff ride on the trail. A suspension set up for  
trail riding would bottom out harshly on a snow-cross course.  
A decal outlining rear suspension set-up options is located either under  
the hood or on the clutch cover. It provides a guideline for initial  
suspension set-up. Additional adjustments can be made from this  
point. Make adjustments to one area at a time so you can evaluate the  
change. For further assistance, see your dealer.  
Suspension Performance Tips  
S Rider weight usually determines the position at which the spring pre-  
load should be set. However, this may vary with riding style. With  
a little experimentation, each rider can find a preferred set-up. These  
adjustments are easy to make, involve very little time or effort, and  
greatly affect the ride.  
S A new rail slide will offer improved performance over a worn rail  
slide. It can also improve top speed.  
S 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.  
S Polaris offers track kits for improved flotation in deep snow. See  
your dealer for assistance.  
NOTE:  
Keep the suspension pivot points lubricated. This will reduce  
moisture and rust build-up and ensure proper function of the  
suspension components. Grease rear suspension pivots before  
adjusting the rear suspension. Refer to Suspension Maintenance  
beginning on page 94.  
34  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
IQ Rear Suspension Adjustments  
Rear Torsion Spring Tension  
To adjust rear torsion spring tension, rotate the three-position cam  
using the engine spark plug tool. Different rate torsion springs are  
available if a firmer ride is desired. Contact your dealer for more  
information.  
The following information is provided only as a guideline to be used  
for initial suspension set-up. Your set-up may vary based on your  
desired riding style.  
2a  
2b  
c  
1
1 - Turn the knob toward the “S” for a softer ride  
Turn the knob toward the “H” for a stiffer ride  
2a -Soft Tension - long end of cam to front  
2b -Medium tension - short end of cam up  
2c -Firm tension - long end of cam up  
35  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
IQ Rear Suspension Adjustments  
Suspension Coupling  
On all Polaris snowmobile rear suspensions, there are two torque arms  
that control the movement of the rail beam. Prior to the advent of  
suspension coupling, these torque arms could move independently of  
each other. Rear suspension coupling links the movement of the front  
and rear torque arms to each other. There are two types of rear  
suspension coupling.  
Front Rear Scissor Stop (FRSS)  
The front rear scissor stop (FRSS) couples the movement of the front  
torque arm with the rear torque arm and limits the amount of  
independence between the movement of the front torque arm and the  
rear torque arm.  
When hitting a bump, the front torque arm starts to compress. The  
FRSS links that movement to the rear torque arm, causing it to  
compress and raise the rear suspension up as one, allowing the  
suspension to hit the bump only once and eliminating kickback. Your  
FRSS is preset at the factory.  
36  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
IQ Rear Suspension Adjustments  
Rear Rear Scissor Stop (RRSS)  
The rear rear scissor stop (RRSS) couples the movement of the rear  
torque arm with the front torque arm and limits the amount of  
independent movement between the rear torque and the front torque  
arm.  
Adjusting the RRSS either allows more weight to transfer to the rear  
for more traction, or allows less weight to transfer to the rear, resulting  
in improved cornering performance. An adjustment dot is located on  
the RRSS. This dot is on the longest end of the scissor stop.  
Rear Rear Scissor Stop - Attributes  
Moving the RRSS to a higher position, or forward hole, will have the  
following effects on the suspension:  
S Reduced weight transfer.  
S Improved chatter bump ride.  
S Improved cornering performance.  
37  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
IQ Rear Suspension Adjustments  
Weight Transfer During Acceleration  
IQ Rear Rear Scissor Stop (RRSS)  
The preferred method for controlling weight  
transfer during acceleration of the IQ rear  
suspension is by adjusting the RRSS. Use the  
scissor stop tool (1) located in your tool kit to  
make the adjustments.  
1
To decrease weight transfer under acceleration  
(for improved cornering), rotate the RRSS to  
a higher position.  
To increase weight transfer or ski lift during acceleration, move the  
RRSS to the rearward upper position. The RRSS may also be rotated to  
a lower position for even more weight transfer if desired.  
A - Low Position - This setting will increase weight transfer.  
B - Medium Position - This setting is the production setting and will  
provide the best overall trail riding.  
C - High Position - This setting will decrease weight transfer.  
D - Rearward Upper Position (optional hole location) - This setting  
will increase weight transfer.  
NOTE:  
Your dealer can help you with initial set-up and additional set-up  
instructions to help you achieve an optimum ride.  
z
C
D
A
B
38  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
Handlebar Adjustments  
Handlebar with Riser Block  
1. Remove the handlebar  
cover to expose the  
handlebar mounting hardware.  
2. Using a 1/4” Allen wrench,  
loosen the two bolts on the  
bottom of the riser or the two  
bolts on the top of the riser,  
depending on the type of  
adjustment required.  
3. Adjust the handlebar to the  
desired angle. Be sure the  
handlebar, brake lever and  
throttle lever operate smoothly  
and do not hit the gas tank,  
windshield or any other part of  
the machine when the handlebar is turned fully to the left or right.  
4. Torque the handlebar adjuster block bolts to 11-13 ft. lbs. (15-17.6  
Nm).  
5. Replace the handlebar cover.  
39  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
Accessories  
Polaris offers a wide range of accessories for your snowmobile to help  
make each ride more enjoyable. See your dealer for a complete list of  
accessories.  
Use only Polaris parts and accessories on your Polaris snowmobile.  
Use of unapproved parts and accessories may result in:  
S Non-compliance with government/industry requirements  
S Voiding of warranty  
S Personal injury to self or others  
This applies to, but is not limited to brakes, clutches, fuel systems, and  
exhaust systems.  
NOTE:  
Exhaust systems are critical safety areas that must use approved  
Polaris parts. Please see your Polaris dealer for service.  
40  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
Accessories  
Traction Products  
Another way to tailor your machine is to install traction products. See  
your dealer about installing studs and/or carbides. Many tracks with  
deep lug designs cannot be studded, but your dealer will be able to  
offer advice and assistance.  
NOTE:  
Before equipping your machine with traction products, be aware of  
the laws in your area pertaining to the use of traction products.  
Track studding will enhance braking control on hard-packed snow or  
ice, but extreme caution is still required on such surfaces. Steering  
ability may be reduced on hard-packed snow or ice.  
A skag is a replaceable bar attached to the underside of the ski to assist  
in turning the snowmobile and to prevent ski wear caused by contact  
with roads and other bare terrain. The addition of carbide skags is  
recommended with studded tracks to help maintain proper vehicle  
steering and control. Similarly, if your machine is equipped with  
carbide skags or you’re adding them, it may be necessary to add track  
studs to maintain proper vehicle control. Proper balance must be  
maintained between the number of studs and the length of carbide on  
skags. The more studs used, the longer the carbide on the skags should  
be. See your dealer’s track studding chart for recommended studding  
and skags.  
Inspect skags and studs frequently. Worn studs or skags may reduce  
steering and braking control on hard-packed snow and ice. Replace  
worn studs and skags to maintain proper balance and vehicle control.  
When studded tracks are used, increased wear to the brake pads will  
result from increased braking. Extended-wear brake pad kits are  
available. See your dealer for more information.  
41  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
Accessories  
CAUTION  
Aggressive studding patterns may require grinding protruding stud bolts  
flush to prevent idler wheel damage. Maintain track tension on studded  
tracks on the tight side of the spec to prevent heat exchanger damage.  
Center of stud must be at least 1 1/8(2.86 cm) from outside edge of the  
track.  
CAUTION  
If traction products are added to the track, wear strips must be installed in  
the tunnel to avoid excessive wear.  
Never add shims to the wear strip. Track damage will result because of  
lack of clearance between upper carrier wheels and track.  
Use of studs longer than the recommended length on machines  
equipped with center coolers will result in center cooler damage or  
damage to the tunnel.  
Use only Polaris traction products on your snowmobile. Track  
warranties are void if track damage or failure results from improper or  
excessive stud installation or the use of non-Polaris traction products.  
WARNING  
Loss of control can result in serious personal injury or death. Proper  
balance of traction products on the skis and track must be maintained to  
obtain proper vehicle control on hard-packed snow or ice. See your  
dealer for assistance.  
42  
Download from Www.Somanuals.com. All Manuals Search And Download.  
THE PERFECT FIT  
Accessories  
Wear Strips  
Polaris IQ models are manufactured with tunnel wear strips or wear  
strip coolers installed. To avoid excessive tunnel wear, tunnel wear  
strips must be installed whenever track studding is used.  
Wear strips are designed for a specific stud length. See your dealer’s  
studding chart for recommended traction accessories.  
Components as viewed from the rear of the track:  
1. Top of tunnel  
2. Wear strip  
3. Track  
4. Wearstrip mounting holes  
1
2
4
3
CAUTION  
Whenever wear strips are relocated, be sure there’s adequate stud  
clearance to the heat exchangers. Lack of clearance may result in  
damage to heat exchangers.  
43  
Download from Www.Somanuals.com. All Manuals Search And Download.  
PRE-RIDE INSPECTIONS  
Pre-Ride Checklist  
Inspect all items on the checklist for proper operation or condition  
before each use of the snowmobile. Procedures are outlined on the  
referenced pages. Look for a checkmark (n) on the referenced pages  
to locate the pre-ride inspection items.  
See Page  
84, 85  
48  
Item  
Drive Belt Condition  
Steering System  
Recoil Rope  
48  
Coolant Level  
73  
Park Brake Lock/Brake Lever/Brake System  
Auxiliary Shut-Off Switch (Engine Stop Switch)  
Taillight/Brakelight/Headlight  
Suspension Mounting Bolts  
Skags (Wear Bars)  
47, 77  
49  
49  
--  
41, 93  
48  
Hood Straps/Latches  
Seat Latches (if equipped)  
Throttle Lever  
--  
45  
Rear Wheel Idler Bolts  
89, 94  
49  
Tether Switch/Strap  
Track Alignment/Condition  
Rail Slide Condition  
89, 90  
94  
Chaincase Oil Level  
66  
Injection Oil Level (600RR)  
55  
44  
Download from Www.Somanuals.com. All Manuals Search And Download.  
PRE-RIDE INSPECTIONS  
Before Starting the Engine  
WARNING  
Worn, damaged, or malfunctioning components may cause serious injury  
or death. Before starting the engine, check all components to be sure of  
proper operation.  
Read and Understand Your Owner’s Manual  
Read the Owner’s Manual completely and refer to it often. We’ve  
attempted to provide as much information as possible to alert you to  
the safety requirements of snowmobiling.  
n Check Throttle and Brake for Proper Operation  
The throttle and brake are the primary controls of your snowmobile. If  
either should malfunction, loss of control could result.  
Make sure the throttle lever compresses evenly and smoothly. The  
lever should immediately return to the idle position without binding or  
hesitation. If the throttle does not function smoothly, DO NOT start  
the engine. Have the throttle serviced immediately.  
The need for a properly functioning brake is critical. Your snowmobile  
is equipped with the highest quality brake system available. Check the  
brakes for correct operation before starting the engine.  
45  
Download from Www.Somanuals.com. All Manuals Search And Download.  
PRE-RIDE INSPECTIONS  
Before Starting the Engine  
n Hydraulic Brakes  
Always check the  
following items to assure  
proper operation before  
starting the engine.  
1/2(1.3 cm)  
Brake Lever Travel  
Squeeze the brake lever.  
It should move no closer  
to the handgrip than 1/2″  
(1.3 cm). A smaller  
distance indicates low brake fluid level or air in the hydraulic system.  
Refer to the brake bleeding information on page 80.  
Lever Feel  
If the brake lever feels “spongy” when squeezed, check the brake fluid  
level and condition. Add fluid as needed. See page 79.  
Check for the presence of air in the fluid system. See page 80 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.  
46  
Download from Www.Somanuals.com. All Manuals Search And Download.  
PRE-RIDE INSPECTIONS  
Before Starting the Engine  
n Parking Brake Lever Lock  
Your snowmobile may have a parking brake lever lock located over the  
brake lever. Use the parking brake lever lock only when you want the  
machine to remain stationary; for example, when parked on an incline  
for a period of five minutes or less.  
2
3
1. Brake Lever  
1
2. Parking Brake Lever Lock  
3. Master Cylinder  
Reservoir / Cover  
Lock Engagement  
To engage the lock, squeeze the brake lever tightly and push forward  
on the lock. Hold the lock forward while releasing the brake lever.  
NOTE:  
If the brake handle is squeezed tightly enough, the lock will move  
freely into place. Do not force the lock or it may break.  
The brake light on the console will light up when the parking brake  
lever lock is set and the engine is running. It will also be lit when the  
service brake is in use. If the parking brake light does not come on  
when the parking brake or service brake is in use, have it serviced by  
your dealer.  
Lock Release  
To release the lock, squeeze the brake lever tightly and release it. The  
lock will return to the unlocked position.  
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.  
47  
Download from Www.Somanuals.com. All Manuals Search And Download.  
PRE-RIDE INSPECTIONS  
Before Starting the Engine  
n Check for Proper Operation of Steering System  
Manually turn the skis completely to the right and to the left. If any  
difficulty is encountered, check for ice and snow build-up that may be  
obstructing the steering linkage. Make sure all greasable components  
are properly lubricated.  
n Track Inspection  
WARNING  
Always inspect the track for damage before using the vehicle. Operating  
the snowmobile with a damaged track increases the possibility of track  
failure, which could cause loss of control resulting in serious injury or  
death.  
Use of traction products such as studs increases the possibility of track  
damage and/or failure. Driving at high speeds for extended periods of  
time in marginal lubrication could severely damage track rods, break  
track edges, and cause other track damage. Examples of marginal  
lubrication would include frozen bodies of water without snow cover,  
icy trails, and no-snow conditions.  
NOTE:  
Track damage or failure caused by operation on ice or poor  
lubrication conditions voids the track warranty.  
n Check 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  
snowmobile.  
n Check Recoil Rope  
Inspect the recoil rope and handle for excessive wear, and make sure  
the knot securing the rope inside the handle is secure. If excessive  
wear is found, see your Polaris dealer for replacement.  
48  
Download from Www.Somanuals.com. All Manuals Search And Download.  
PRE-RIDE INSPECTIONS  
Start the Engine and Check  
Before starting the engine, always refer to all safety warnings  
pertaining to snowmobile operation. Never start your snowmobile  
without checking all components to be sure of proper operation. See  
Before Starting the Engine beginning on page 45.  
n Engine Stop Switch: Check the auxiliary shut-off switch for  
proper operation. Push the switch down to stop the engine. Pull it  
up to allow restarting.  
n Tether Switch: Make sure the engine shuts off when the tether is  
removed from the switch.  
n Lighting: Check the headlight (high and low beam), taillight, and  
brake light. Replace burned out lamps before operating.  
n Operating Area: Before driving away, check your surroundings.  
Be aware of obstacles and make sure bystanders are a safe distance  
from the machine.  
49  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Engine Break-In  
No single action on your part is as important to long, trouble-free  
machine life as proper break-in of a new or rebuilt engine.  
Always premix the initial fuel and future fuel as outlined in the tables  
on page 51.  
CAUTION  
Excessive heat build-up during the first three hours of operation will  
damage close-fitted engine parts. Do not operate at full throttle or high  
speeds for extended periods during the first three hours of use. Vary the  
throttle openings and machine speeds to reduce friction on all close-fitting  
machined parts, allowing them to break in slowly without damage.  
Use of any lubricants other than those recommended by Polaris may  
cause serious engine damage. We recommend the use of Polaris  
lubricants for your vehicle.  
Drive with extra caution during the break-in period. Perform regular  
checks on fluid levels, lines, and all other important areas of the machine.  
Oil Recommendations  
Never mix brands of oil. Serious chemical reactions can cause system  
blockage, resulting in serious engine damage. They may also be  
incompatible and the result could be sludge formation, filter blockage,  
and reduced cold weather flow rates. All Polaris oils are compatible  
with each other. See page 99 for the part numbers of Polaris products.  
Recommended Oils  
600 IQ Racer  
600RR  
2-Cycle Racing Oil  
VES II 2-Cycle Oil or 2-Cycle Racing Oil  
600 IQ Racer  
The only source of engine lubrication for this engine comes from  
lubrication added to the fuel. Always premix the fuel.  
600RR  
Engine lubrication comes from oil added to the fuel and oil injection  
systems. Always check and fill the oil tank when refueling. See page  
55.  
CAUTION  
Serious engine damage can occur without the proper lubrication. Check  
the oil tank level often during the first tank of fuel. If the oil level doesn’t  
go down, contact your dealer immediately.  
50  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Engine Break-In  
Fuel Recommendations  
CAUTION  
Using fuels with a lower than recommended octane or operating with  
obstructed fuel systems will result in serious and costly engine damage.  
Always use the recommended fuels for your machine.  
600 IQ Racer Fuel  
Always use premium non-oxygenated (92 octane) fuel.  
600RR Fuel  
Polaris recommends the use of 91 octane or higher fuel. Although 87  
octane fuel is usable, some engine performance will be lost and fuel  
economy will decrease. Do not use lower than 87 octane fuel. Do not  
use fuel containing more than 10% ethanol (including E85).  
Fuel Premix  
Initial Tankful of Fuel  
Fuel  
Oil  
Ratio  
28:1  
40:1  
600 IQ Racer  
600RR  
3.5 gal (13.2 l)  
5 gal (19 l)  
16 oz. (473 ml)  
16 oz. (473 ml)  
Future Fuel  
Fuel  
3.5 gal (13.2 l)  
All  
Oil  
14 oz. (414 ml)  
None  
Ratio  
32:1  
600 IQ Racer  
600RR  
None  
Fuel System Deicers  
When using non-oxygenated fuel, use an isopropyl-based fuel system  
deicer. Add one to two ounces per gallon (8-16 ml per liter) of gasoline  
to prevent engine damage resulting from fuel system icing and lean  
fuel mixtures. Never use deicers or additives containing methanol.  
Polaris also recommends the use of Carbon Clean Plus. See page 106  
for the part numbers of Polaris products.  
NOTE:  
When using oxygenated fuel containing ethanol, additional alcohol  
deicers or water absorbing additives should not be used.  
51  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Engine Break-In  
Fuel Recommendations  
WARNING  
Gasoline is highly flammable and explosive under certain conditions.  
S Always exercise extreme caution whenever handling gasoline.  
S Always refuel with the engine stopped, and outdoors or in a well  
ventilated area.  
S Do not overfill the tank. Do not fill the tank neck.  
S Do not smoke or allow open flames or sparks in or near the  
area where refueling is performed or where gasoline is stored.  
S If gasoline spills on your skin or clothing, immediately wash it off  
with soap and water and change clothing.  
S Never start the engine or let it run in an enclosed area. Engine  
exhaust fumes are poisonous and can cause loss of conscious-  
ness or death in a short time.  
S Turn the fuel valve off whenever the snowmobile is stored or  
parked.  
WARNING  
The engine exhaust from this product contains chemicals known to cause  
cancer, birth defects or other reproductive harm.  
Operate this vehicle only outdoors or in well-ventilated areas.  
52  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Starting the Engine  
Starting a Cold Engine  
Do not depress the throttle until the engine starts.  
1. Attach the tether cord to the tether switch.  
2. Pull the kill switch (shut-off switch) up to RUN.  
3. Flip the choke toggle to FULL CHOKE.  
4. Grasp the starter handle and pull slowly until the recoil engages,  
then pull abruptly to start the engine.  
CAUTION  
Don’t pull the starter rope to full extended position or allow it to snap back  
into the housing. Damage may result.  
To avoid personal injury and/or engine damage, do not operate the recoil  
pull-rope starter while the engine is running.  
5. After the engine starts, flip the choke toggle to the OFF position.  
If the engine slows or wants to stop, use intermittent choking to the  
HALF CHOKE position.  
6. Warm up the engine before operating. See page 54.  
Starting a Warm Engine  
1. Attach the tether cord to the tether switch.  
2. Pull the kill switch (shut-off switch) up to RUN.  
3. Grasp the starter handle and pull slowly until the recoil engages;  
then pull abruptly to start the engine.  
If the engine does not start on the first pull, slightly depress the throttle  
with your left hand (no more than 1/4open), and pull the rope with  
your right hand. When the engine starts, immediately release the  
throttle.  
53  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Engine and Track Warm-Up  
WARNING  
A loose track or flying debris could cause serious personal injury or  
death. Stand clear of the front of the machine and the moving track.  
Never hold the snowmobile up or stand behind it while warming up the  
track. Do not use excessive throttle during warm-up or when the track is  
free-hanging. Be sure the rear support is stable.  
WARNING  
Use of traction products such as studs, ice growsers, etc. will increase  
the possibility of track damage and/or failure. This could cause loss of  
control, resulting in serious injury or death. Always inspect for track  
damage before operating the snowmobile.  
Follow these steps to ensure proper  
warm-up of the engine, drive train and  
track.  
1. Use an appropriate stand to securely  
support the rear of the snowmobile at  
the rear bumper. The track should be  
approximately 4(10 cm) off the  
ground.  
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.  
NOTE:  
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 machine to the ground.  
5. Grasp the skis by their front loops and move them from side to  
side. This will loosen frozen snow from the ski bottoms, allowing  
the machine to move forward more easily.  
6. The engine, drive system and track are now properly warmed up  
and the machine may be driven following normal safety practices.  
54  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Slide Rail and Track Cooling  
CAUTION  
Inadequate cooling and lubrication will lead to overheating of the slide rail  
and track, resulting in premature wear and failure. Reduce speeds and  
frequently drive into fresh snow to allow adequate cooling and polishing  
of the slide rail and track surfaces. Avoid operating on ice, hard-packed  
surfaces or roads.  
Injection Oil Level (600RR)  
The low oil indicator light will alert the operator if the oil level is low.  
Visually check for oil in the tank (bottle). Add oil before further  
operation of the snowmobile. See page 50 for oil recommendations.  
Maintaining the proper oil level will prevent system aeration and  
possible loss of pumping action, which could result in engine damage.  
This is especially important when the machine is operated in  
mountainous terrain.  
CAUTION  
Operating the snowmobile without adequate engine lubrication can result  
in serious engine damage. Always check the oil level when refueling. Add  
oil as needed.  
Always maintain a visible level of oil in the tank. If oil is not visible,  
continued operation may cause serious engine damage. See page 50  
for oil recommendations.  
The Polaris oil cap on the oil bottle is vented to allow proper oil flow.  
See your Polaris dealer for recommended replacement parts.  
55  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Carburetion  
Proper carburetor adjustment is critical. A lean mixture (too much air,  
too little fuel) may result in piston burning, bearing failure, or  
complete engine failure. A rich mixture (too much fuel, too little air)  
may foul plugs and cause generally poor engine performance.  
A lean mixture may be caused by things like fuel line restrictions,  
foreign matter in the carburetor or clogged fuel filters. A rich mixture  
may be caused by snow build-up on the pre-filter in the air intake  
system. Either condition may be caused by improper carburetor  
adjustment.  
WARNING  
Improper carburetor adjustments may result in operator safety hazards as  
well as serious engine damage. Always have your Polaris dealer perform  
any carburetor adjustments.  
Jetting Guidelines  
Changes in altitude and temperature affect air density, which is the  
amount of oxygen available for combustion. In low elevations and  
cold temperatures, the air has more oxygen. In higher elevations and  
higher temperatures, the air is less dense.  
Carburetors on most Polaris models are calibrated for an altitude of  
0-2000 ft. (0-600 meters) and ambient temperatures between -10 to +10  
F (-23 to -12 C). All carburetors must be re-calibrated if operated  
outside this production temperature and/or altitude range. The main jet  
installed in production is not correct for all altitudes and/or  
temperatures.  
CAUTION  
A main jet that’s too small will cause a lean operating condition and may  
cause serious engine damage. Jet the carburetors carefully for elevation  
and temperature according to the jetting charts in your Owner’s Manual  
Supplement.  
NOTE:  
It’s the owner’s responsibility to ensure that the correct jets are  
installed in the machine for a geographical area. Be very careful  
when jetting down in warm weather. As the weather turns colder it  
will be necessary to re-jet upward to prevent engine damage. When  
selecting the proper main jet always use the lowest elevation and  
temperature that is likely to be encountered.  
56  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
n Engine Stop Switch  
1
Push down on the engine stop  
switch (1) to stop the engine in an  
emergency. To restart the engine,  
pull the switch up to the ON  
position.  
Emergency Stopping  
The following chart lists methods for stopping the snowmobile in the  
event of an emergency. Refer to page 57 for more information about  
the engine stop switch.  
SYSTEM  
WHAT IT DOES  
THROTTLE  
CONDITION  
Brake  
Choke  
Slows jackshaft  
All  
Floods engine  
Half throttle or less  
Engine Stop Switch  
Tether Switch  
Interrupts ignition circuit  
Interrupts ignition circuit  
All  
All  
WARNING  
Excessive or repetitive use of brakes for high speed stops will cause an  
overheated brake system. This overheated condition could cause  
sudden loss of brakes and/or fire, resulting in serious injury or death.  
When traveling on long downhill stretches, pump the brakes. Riding the  
brakes may cause the brake system to overheat and result in brake  
failure.  
57  
Download from Www.Somanuals.com. All Manuals Search And Download.  
OPERATION  
Daily Storage  
At the end of each ride, park the  
snowmobile on a level surface and  
support it at the rear with an appropriate  
track stand. The track should be  
suspended approximately 4(10 cm) off  
the ground. Cover the machine with an  
appropriate cover.  
Towing  
WARNING  
Objects towed with a rope have no braking power and can easily collide  
with the rear of the snowmobile or other objects, resulting in serious injury  
or death. DO NOT tow toboggans, sleds, saucers, or any type of vehicle  
with a rope. 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. Remove the drive belt before towing, and have a rider on  
the towed snowmobile to operate the brake and steering when  
necessary.  
CAUTION  
Towing a disabled snowmobile with the drive belt in place can result in  
serious damage to the engine and drive system. Always remove the  
drive belt from a disabled snowmobile before towing.  
58  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Emission Control Information  
Any qualified repair shop or qualified person may maintain, replace, or  
repair the emission control devices or systems on your snowmobile.  
Emission Control Label  
Your snowmobile is equipped at the time of sale with an emission  
control information (ECI) label and a factory-installed emissions  
information hangtag. These items are required by U.S. Environmental  
Protection Agency regulations. The ECI label is permanently affixed to  
either the right side of the tunnel or the engine recoil cover. The ECI  
label should not be removed, even after you purchase the snowmobile.  
You may remove the factory-installed emissions information hangtag,  
which is intended solely for your use in making a purchasing decision.  
Emission Control Maintenance Requirements  
Your snowmobile is certified to operate on gasoline with a minimum  
octane level of 91 (R+M)/2 for the 600 IQ Racer and 87 (R+M)/2 for  
the 600RR. The emission control system designation per SAE J1930 is  
EM. If your snowmobile is equipped with a check engine light and it  
comes on, you must take your snowmobile to a qualified dealer for  
diagnostic service. Specifications and adjustments for engine tune-ups  
are located in the Service Manual, which is available to your qualified  
service technician. Reverse (if equipped) must not be engaged during  
engine tune-ups.  
Owner’s Responsibilities  
Please read the Snowmobile Engine Emissions Limited Warranty on  
page 111, and read the maintenance section of your owner’s manual.  
You are responsible for ensuring that the specified maintenance is  
performed.  
Polaris recommends that you contact an authorized Polaris dealer to  
perform any service that may be necessary.  
59  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Polaris Recommended Maintenance Program  
To ensure many trouble-free miles of snowmobiling enjoyment, follow  
recommended regular maintenance and service checks outlined in this  
manual. Record services performed in the Maintenance Record at the  
rear of this manual.  
The recommended maintenance schedule on your snowmobile calls for  
service and maintenance inspections at 150 miles (240 km), 500 miles  
(800 km), and 1000 miles (1600 km). These inspections should be  
performed by a qualified service technician. For continued optimum  
performance and component life, continue maintenance checks at 1000  
mile (1600 km) intervals.  
All necessary replacement parts and labor incurred, with the exception  
of authorized warranty repairs, become the responsibility of the  
registered owner. 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 adjust your  
snowmobile. If you’re not familiar with safe service or adjustment  
procedures and the use of tools, or if you don’t feel comfortable  
performing these tasks yourself, contact an authorized Polaris dealer  
for service.  
CAUTION  
Hot components can cause damage to plastic. Always make sure the  
exhaust system and engine have cooled before tipping the snowmobile  
on its side for service or inspection.  
60  
Download from Www.Somanuals.com. All Manuals Search And Download.  
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.  
See  
Page  
Frequency  
Item  
150 mi.  
500 mi.  
1000 mi.  
2000 mi.  
Pre-  
(240 km) (800 km) (1600 km) (3200 km) Season  
Clutch  
Clutch Offset Alignment  
(without belt)  
83  
I
I
I
Drive Belt Condition  
Clutches (disassemble)  
Belt Tension  
84  
83  
--  
I
C
I
I
C
I
I
C
I
I
I
I
Clutch Sheaves  
83  
I
I
I
Engine  
Engine Mounts  
--  
--  
I
I
I
I
I
I
I
I
Recoil Rope  
Engine Mounting Plate  
Engine Torque Stop  
Cylinder Head Bolts  
Cylinder Base Nuts  
Ignition Timing BTDC  
VES System  
--  
I
I
I
86  
--  
I
I
I
I
I
I
I
--  
I
I
I
I
--  
I
I
I
--  
C
I
C
I
C
R
I
I
I
Coolant Level  
73  
N/A  
--  
Water Pump Drive Belt  
Coolant Hose  
I
I
I
I
I
I
I
Heat Exchangers  
Coolant Circulation  
Coolant Leaks  
74  
--  
I
I
I
I
I
I
I
I
--  
I
I
I
I
I
I
I
Spark Plug Condition  
Exhaust Pipe  
68  
72  
72  
I
I
I
I
Exhaust Retaining  
Springs  
I
I
I
I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)  
C - Clean R - Replace L - Lubricate  
61  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Periodic Maintenance Interval Table  
See  
Page  
Frequency  
Item  
150 mi.  
500 mi.  
1000 mi.  
2000 mi.  
Pre-  
(240 km) (800 km) (1600 km) (3200 km) Season  
Brakes  
Hose Routing  
--  
--  
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Hose Condition  
Fluid Leaks  
--  
Brake Pads  
Brake Disc  
77  
--  
Parking Brakes  
Brake System  
Brake fluid  
47  
45, 77  
79  
R
Fuel Management  
Pilot Air Screws  
Carburetor (synchronize)  
Idle RPM  
--  
56  
--  
I
I
I
I
I
I
I
I
I
I
I
Throttle Lever  
45  
--  
I
I
I
I
Oil Pump Lever (600RR)  
(synchronize)  
I
I
I
Throttle Cable  
Choke Cable  
Vent Lines  
65  
65  
--  
L
L
I
L
L
I
L
L
I
Throttle Position Sensor  
Choke  
--  
I
I
I
65  
70  
70  
69  
69  
--  
I
I
I
Fuel Filter  
R
I
R
I
Fuel Lines  
I
I
I
I
I
I
Oil Filter (600RR)  
Oil Lines (600RR)  
Air Box  
R
R
I
R
R
I
Drain and Water Traps  
71  
Electrical  
Auxiliary Shut-Off Switch  
Taillight  
49  
49  
49  
49  
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Brakelight  
Headlight  
62  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Periodic Maintenance Interval Table  
Frequency  
See  
Page  
Item  
150 mi.  
500 mi.  
1000 mi.  
2000 mi.  
Pre-  
(240 km) (800 km) (1600 km) (3200 km) Season  
Chassis  
Ski Toe Alignment  
--  
--  
I
I
I
I
I
I
I
I
I
I
I
I
Suspension  
Mounting Bolts  
I
I
I
I
C
I
Steering Fasteners  
--  
--  
Rear Suspension  
Fasteners  
Suspension Shock Oil  
Cooling Fins and Shroud  
Skags (Wear Bars)  
Ski Saddle/Spindle Bolts  
Ski Pivots  
--  
I
I
I
I
I
I
I
I
--  
41  
64  
65  
65  
65  
64  
64  
I
I
I
I
I
I
I
I
I
I
L
L
L
L
L
L
L
L
L
L
L
L
L
L
L
L
I
Ski Spindle  
I
Steering Post U-Joint  
Steering Arm(s)  
L
I
Upper / Lower Steering  
Post Support Bracket  
L
L
L
L
I
Drive Chain Tension  
Hood Straps  
76  
48  
89  
88  
--  
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Rear Wheel Idler Bolts  
Idler Bolt Jam Nut  
Camber Alignment  
Radius Rod Bushings  
Handlebar Centering  
Tether Switch and Strap  
Track Alignment  
--  
I
I
I
I
I
I
I
I
I
--  
49  
89  
88  
--  
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
Track Tension  
Front Limiter Strap  
Rail Slide Condition  
Chaincase Oil  
94  
66  
N/A  
I
I
I
I
I
I
R
R
Gearcase Oil  
I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)  
C - Clean R - Replace L - Lubricate  
63  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Lubrication  
Lack of lubrication will adversely affect your ride and the life of  
components. Lubricate with Polaris Premium All Season Grease at 500  
miles (800 km) initially, every 1000 miles (1600 km) after that, and  
before off-season storage each year. A grease gun kit, complete with  
grease and adaptors, is available to lubricate all fittings on Polaris  
snowmobiles. See page 99 for the part numbers of Polaris products.  
For more information about suspension lubrication and adjustments,  
see your Polaris dealer.  
NOTE:  
Lubrication points are indicated by a L in the following illustrations.  
Rear Suspension  
64  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Lubrication  
Front Suspension  
Two components of the IQ front suspension and steering require  
lubrication.  
S Grease the left and right spindles. Raise the front end of the ma-  
chine to permit better grease entry into the spindle area.  
S Lubricate the steering post U-joint.  
Throttle Cable  
Lubricate the throttle cable (1) lightly  
with grease or oil. With the engine off,  
turn the handlebars to the left and  
lubricate liberally as shown.  
1
Choke and Cable  
Lubricate the choke slide (2) and cables  
lightly with oil or grease. Before  
turning the engine off, operate the choke  
intermittently to draw moisture out of  
the choke plunger area and reduce the  
possibility of the choke becoming  
frozen.  
2
65  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Lubrication  
n Chaincase Oil Level  
Check the chaincase oil level at the intervals outlined in the  
maintenance charts beginning on page 60.  
To check the oil level, place the machine on a level surface. The oil  
level should be between the “safe” marks on the dipstick (A). Add  
Polaris synthetic chaincase oil through the dipstick opening. Do not  
overfill. See page 99 for the part numbers of Polaris products.  
Flush the chaincase after the first 500 miles, then every 1000 miles or  
seasonally. Clean the magnetic plug (B) whenever checking or  
changing lubricant.  
A
B
CAUTION  
Mixing brands or using non-recommended lubricants could result in  
excessive wear to internal components. Always use  
Polaris-recommended products for your vehicle.  
66  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Spark Plugs  
A spark plug with a heat range too high will cause engine damage. A  
spark plug with a heat range too low will cause excessive fouling and  
engine malfunctioning.  
In selecting a spark plug heat range for production, a manufacturer  
assumes that the engine will be operated under extreme heavy duty  
conditions and selects a spark plug that will protect the engine from  
internal damage if the purchaser actually does operate the engine in this  
manner. This selection could cause the customer who normally  
operates the engine under medium or light duty to have spark plug  
failure. Refer to your Owner’s Manual Supplement for the specific  
spark plug to be used in your machine.  
CAUTION  
A spark plug with a heat range too high will always cause engine damage  
if the engine is operated in conditions more severe than intended for that  
plug. Always use the spark plugs recommended for your snowmobile.  
See your Owner’s Manual Supplement.  
A new engine can cause temporary spark plug fouling due to the  
preservative added during the assembly process. Avoid prolonged idle  
speeds, which cause plug fouling and carbonization.  
S Use recommended spark plugs with the proper gap. Refer to your  
Owner’s Manual Supplement for specific information.  
S Spark plug torque is 18-22 ft. lbs. (24-30 Nm).  
S Always carry spare spark plugs in case of an emergency.  
CAUTION  
Using non-recommended spark plugs can result in serious engine  
damage. Always use Polaris-recommended spark plugs.  
67  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Spark Plugs  
Spark plug condition is indicative of engine operation. The spark plug  
firing end condition should be read after the engine has been warmed  
up and the vehicle has been driven at higher speeds. Immediately  
check the spark plug for correct color.  
WARNING  
A hot exhaust system and engine can cause serious burns. Wear  
protective gloves when removing a spark plug for inspection.  
NOTE:  
Incorrect fuel mixture can often cause a spark plug to appear too  
dark or too light in color. Before changing spark plug heat ranges,  
be sure the correct main jet is installed in the carburetor(s). Refer to  
the Owner’s Manual Supplement or see your dealer.  
1. Normal  
The normal insulator tip is gray, tan or light brown. There will be few  
combustion deposits. The electrodes are not burned or eroded. This  
indicates the proper type and heat range for the engine and the service.  
NOTE:  
The tip should not be white. A white insulator tip indicates  
overheating, caused by use of an improper spark plug or incorrect  
carburetion adjustments.  
2. Wet Fouled  
The wet fouled insulator tip is black. A damp oil film covers the firing  
end. There may be a carbon layer over the entire nose. Generally, the  
electrodes are not worn. General causes of fouling are excessive oil,  
use of non-recommended injection oil, improper use of the choke, or  
incorrect carburetion adjustments.  
Spark Plug Removal and Replacement  
1. Remove the spark plug cap.  
2. Using the special wrench provided in  
the tool pouch, rotate the spark plug  
counterclockwise to remove.  
3. Reverse the procedure for spark plug  
1
installation.  
4. Torque to 18-22 ft. lbs. (24-30 Nm).  
5. Install spark plug cap.  
68  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Intake Filter  
The intake foam filters  
limit snow ingestion into  
the intake system. When  
operating in loose powder  
snow, check the top of the  
foam filters periodically to  
remove any accumulation  
of snow.  
CAUTION  
Operating the snowmobile with the intake filters removed may cause  
carburetor icing. The result will be poor fuel economy or carburetor  
malfunction. Always reinstall the intake filters before operating the  
snowmobile.  
Oil Lines (600 RR)  
Inspect oil line condition every 1000 miles (1600 km).  
Oil Filter (600 RR)  
The oil filter is located at the side of the oil tank. Have your dealer  
change the oil filter and bleed the system annually or every 1000 miles  
(1600 km).  
The direction of the arrows indicates the direction of flow through the  
filter.  
69  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Variable Exhaust System (VES)  
Maintenance of the VES is limited to a periodic inspection and  
cleaning of system components. Every 1000 to 2000 miles (800-1600  
km), bring the machine to an authorized Polaris dealer to have the VES  
disassembled, inspected, and cleaned.  
NOTE:  
To ensure maximum performance and minimize required  
maintenance, follow the oil recommendations on page 50. The use  
of other lubricants may cause improper function of the valve  
mechanism and increase the frequency of required cleaning due to  
excessive build-up of carbon deposits.  
Fuel Pump  
All fuel pump service must be performed by an authorized Polaris  
dealer. Do not attempt to service the fuel pump.  
Fuel Filter/Fuel Lines  
See your Polaris dealer for replacement of the in-tank fuel filter every  
1000 miles (or annually).  
Inspect the fuel lines regularly for signs of deterioration or damage.  
Always check fuel line condition after periods of storage. Normal  
deterioration from weather and fuel compounds may occur. Replace  
worn or damaged fuel lines promptly.  
CAUTION  
Kinking the fuel lines or using a pliers or similar tools to remove fuel lines  
may cause damage to the lines. If a fuel line has been damaged or  
kinked, replace it promptly.  
70  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Carburetor  
The number stamped in the end of the main jet indicates the jet size.  
The jet installed at the time of manufacture is not necessarily correct  
for your elevation. It’s your dealer’s responsibility to make sure the  
correct main jet is installed.  
CAUTION  
Operating the snowmobile with incorrect jetting can result in serious  
engine damage. Have your Polaris dealer perform all carburetor  
adjustments to ensure all adjustments are done correctly.  
Carburetor Adjustments  
The frequency at which the carburetors are synchronized or balanced is  
important. Properly adjusted carburetors can greatly improve engine  
performance, fuel economy, engine life, and reliability.  
If you notice any of the following conditions, the carburetor may need  
adjustment:  
S Hard starting  
S Poor idle  
S Overheated pistons and cylinder walls  
S Plug fouling  
S Poor engine response to various throttle valve openings  
Carburetor Water/Sediment Trap  
Drain the water/sediment traps located at the bottom of each carburetor  
about every 1000 miles (1600 km). Inspect for contamination.  
WARNING  
When draining the traps, fuel spillage will occur. Always work in a well  
ventilated area away from anything that may cause the fuel to ignite, such  
as open flames, sparks, heaters, trouble lights, cigarettes, etc. Review  
the fuel warnings on page 55.  
1. Turn the fuel valve off.  
2. Place a container or shop towels below the plug to catch drained  
fuel.  
3. Slide the clamp away from the drain plug and remove the drain  
plug from the sediment tube.  
4. Wipe residue from the plug and reinstall it. Reposition and tighten  
the clamp.  
5. Repeat the draining procedure for any remaining traps.  
71  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Exhaust System  
Check the exhaust system for wear or damage at approximately 1000  
miles (1600 km). To inspect, allow the engine and exhaust system to  
cool completely. Open the hood and inspect the muffler and pipes for  
cracks or damage. Check for weak or missing retaining springs or  
damper/support grommets.  
WARNING  
Hot exhaust system parts can cause serious burns. Allow adequate time  
for the exhaust system to cool. Never perform this procedure with the  
engine running.  
Engine Cooling  
The cooling system on liquid cooled models consists of the following  
major components:  
S Coolant bottle  
S Water pump  
S Cylinders  
S Heads  
S Inlet and outlet manifolds  
S Pressure cap  
S Heat exchangers  
72  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Engine Cooling  
Coolant Mixture  
The coolant supplied in the system is a 50/50 mixture of  
ethylene-glycol and distilled water. This mixture provides protection  
against freezing at temperatures to -34° F (-37° C). If greater  
protection is required, the percentage of antifreeze to water may be  
increased. Use Premium 60/40 anti-freeze coolant, which is already  
premixed and ready to use. Do not dilute with water. Never exceed a  
60% antifreeze/40% water mixture. Contact you dealer if greater  
protection is required.  
NOTE:  
Never add tap water to the cooling system. Minerals cause deposits  
and may react adversely with the metals in the engine and cooling  
system.  
Coolant High Temperature Indicator Light  
The high temperature indicator light is controlled by a switch in the  
engine cooling system on liquid cooled models. If the engine coolant  
reaches a certain temperature, the switch completes a circuit that turns  
the light on. If you must drive your machine after the high temperature  
indicator light has come on, drive slowly and stop frequently to allow  
the engine to cool down. See your dealer.  
n Coolant Level  
Maintain the coolant level at the “full cold” line on the coolant bottle  
when the engine is cold.  
CAUTION  
Operating the snowmobile with insufficient coolant will result in  
overheating and serious engine damage. Always maintain the coolant  
level as recommended.  
The engine coolant level is controlled by the recovery system. The  
recovery system components are:  
S Coolant bottle or overflow tank  
S Engine filler neck  
S Pressure cap (on some models)  
S Connecting hoses  
73  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Engine Cooling  
Flushing the Cooling System  
To ensure that the coolant maintains its ability to protect the engine,  
the system should be completely drained every two years and a fresh  
50/50 or 60/40 mixture of antifreeze and distilled water should be  
added. This service must be done when the engine is cold. Ask your  
Polaris dealer to check the coolant when he performs the fall tune-up  
on your snowmobile.  
WARNING  
Steam and hot liquids will cause serious burns to your skin. Never bleed  
the cooling system or remove the pressure cap when the engine is warm  
or hot.  
If the pressure cap needs replacement, contact your dealer for the  
correct part. Use of a non-standard pressure cap will not allow the  
recovery system to function properly.  
Bleeding the Cooling System  
CAUTION  
If coolant flow becomes restricted or plugged, coolant loss, air lock or  
engine damage may result. Most cooling systems are equipped with a  
filter that should be periodically inspected or replaced.  
If coolant becomes low in the tank, bleed the system of trapped air  
using the following procedure:  
1. Allow the system to cool completely, then loosen the bleed screw  
and fill the reservoir to the FULL COLD mark. Tighten the screw.  
2. Apply the parking brake and run the engine at idle RPM until the  
thermostat opens (5 to 8 minutes) and stays open.  
NOTE:  
As the thermostat draws in cold coolant from the heat exchangers,  
the cold coolant may close the thermostat. Make sure it opens and  
stays open.  
74  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Engine Cooling  
Bleeding the Cooling System  
3. Tip the snowmobile slightly onto its right side. Cycle the RPM  
from idle to enough RPM (4000) to get coolant to flow, but not  
enough to engage the clutch. This allows air to bleed from the rear  
crossover tube.  
NOTE:  
There must be enough coolant flow to purge the air from the  
crossover hose or rear cooler so you can observe this air reaching  
the bottle.  
4. Tilt the machine slightly onto its left side so that the coolant bottle  
is the highest point in the cooling system. Cycle the RPM as  
outlined in step 3.  
NOTE:  
There must be enough coolant flow to purge the air from the front  
close-off cooler so you can observe the air reaching the bottle.  
5. Return the snowmobile to its upright position and loosen the bleed  
screw at the top of the water outlet manifold. When all trapped air  
has been purged, tighten the screw.  
6. Turn off the engine and release the parking brake. Allow the  
system to cool completely.  
NOTE:  
After cool-down, three (3) or more ounces of coolant may have to be  
added.  
7. Remove the pressure cap and check the coolant level. Add coolant  
to the fill line if necessary.  
75  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Drive Chain Tension  
To obtain correct chain tension:  
1. Rotate the driven clutch  
counterclockwise to move all  
chain slack to the tensioner  
side. Lock the brake lever  
lock, or have an assistant hold  
the brake lever firmly.  
B
2. Loosen the adjuster bolt jam  
nut (A).  
A
3. Finger tighten the adjuster  
bolt (B) until it can no longer  
be adjusted by hand, then  
back off 1/4 turn.  
4. Tighten the jam nut while  
holding the adjuster bolt.  
5. The chain is now tensioned. Release the brake lever lock.  
76  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
n Hydraulic Brake Inspection  
Frequently inspect the  
brake lever reserve.  
Squeeze the brake lever.  
It should move no closer  
to the handgrip than 1/2″  
(1.3 cm). A smaller  
1/2(1.3 cm)  
distance indicates low  
brake fluid level or air in  
the hydraulic system.  
Refer to the brake bleeding  
information on page 80.  
Brake pads must be replaced when the brake pad material becomes  
thinner than the backing plate (approximately 1/16/1.6 mm). A kit is  
available for replacing brake pads. See your dealer.  
WARNING  
Brake failure during operation can result in serious injury or death.  
Properly functioning brakes are vital to your safety. Be sure the brake  
pads do not drag on the disc and that brake lever travel is not excessive.  
Always replace brake pads when the brake pad material becomes thinner  
than the backing plate (approximately 1/16/1.6 mm).  
77  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Brakes  
Brake Components  
4
2
1. Brake Caliper  
2. Chaincase  
3. Brake Disc  
4. Backing Plate  
5. Brake Pad Material (Replace when thickness is less than 1/16).  
Excessive Brake Lever Travel  
Hydraulic brakes are self-adjusting, but if excessive brake pad  
clearance develops, as described on page 77, the machine should be  
returned to an authorized Polaris dealer for inspection and adjustment.  
78  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Brakes  
Brake Fluid  
WARNING  
After opening a bottle of brake fluid, always discard any unused portion.  
Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it  
rapidly absorbs moisture from the air. The moisture causes the boiling  
temperature of the brake fluid to drop, which can lead to early brake fade  
and the possibility of accident or severe injury.  
WARNING  
Keep the master cylinder cover free of dirt and debris. The vent slits allow  
for diaphragm movement, and if they become plugged, movement of  
brake fluid below the diaphragm may be restricted, altering brake  
function.  
CAUTION  
Brake fluid will damage decals, paint and some plastics. Always wipe up  
spills immediately.  
Maintain the brake fluid level between the MIN and MAX marks on  
the master cylinder reservoir. Use only Polaris DOT 4 high temperature  
brake fluid. See page 99 for the part numbers of Polaris products.  
79  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Brakes  
Bleeding the Hydraulic Brake System  
Air in the hydraulic brake system will cause spongy brake lever action.  
Bleed the system before operating the snowmobile.  
WARNING  
Operating the vehicle with a spongy brake lever can result in loss of  
brakes, which could cause an accident and lead to serious injury or  
death. Never operate the vehicle with a spongy-feeling brake lever.  
During the bleeding procedure, keep the brake handle as level as  
possible. The reservoir must be in this position to minimize the  
possibility of air entering the system through the reservoir vent.  
1. Remove brake master cylinder reservoir cover and gasket.  
2. Fill the master cylinder reservoir to between the MIN and MAX  
marks. Reinstall the gasket and cover.  
3. Slip a rubber tube over the ball of the bleeder valve and direct the  
flow of fluid into an approved container.  
4. Squeeze the brake lever a full stroke. Then unscrew the bleeder  
valve 3/4 of a turn to release air.  
5. Close the bleeder valve and release the brake lever.  
6. Repeat steps 4 and 5 until fluid flows from the bleeder valve in a  
solid stream free of air bubbles.  
WARNING  
Overfilling the master cylinder leaves no room for fluid expansion and  
may cause the brakes to lock, resulting in serious injury or death. Always  
add brake fluid to the fill line as recommended.  
7. After bleeding is complete, refill the reservoir to the proper level.  
See page 79.  
8. Reinstall the gasket and cover.  
80  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Headlights  
Headlight Adjustment  
25’ (7.6 m)  
x
x
2(5.1 cm)  
The headlight may be adjusted for vertical aim using the following  
procedure:  
1. Place the snowmobile on a level surface with the headlight  
approximately 25 feet (7.6m) from a wall.  
2. Measure the distance from the floor to the center of the headlight  
and make a mark on the wall.  
3. Start the engine and turn the headlight switch to high beam.  
4. Observe the headlight aim. The most intense part of the headlight  
beam should be aimed 2(5.1 cm) below the mark placed on the  
wall in step 2.  
NOTE:  
Rider weight must be included on the seat.  
5. Turn the adjustment nut (1),  
located inside the hood,  
just below the headlamp  
opening. Turn the knob in or  
out as needed for proper aim.  
1
81  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Headlights  
NOTE:  
Do not touch a halogen bulb with bare fingers. Oil from skin leaves  
a residue, causing a hot spot that will shorten the life of the lamp.  
Removing Halogen Bulbs - High/Low Beam  
1. Pinch the ends of the spring (1)  
together and lift until it releases  
2
from the spring retainer.  
2. Lift spring carefully around  
wire harness (2) and flip to  
outside of housing.  
3
3. With the wire harness attached  
to the bulb (3), withdraw bulb  
from housing.  
1
4. Grasp bulb by metal base and carefully separate bulb from  
harness.  
Installing the Bulb  
1. Hold bulb by metal base and install into wire harness.  
2. Insert bulb into housing.  
3. Carefully flip spring back into housing placing it around wire  
harness.  
4. Squeeze spring together until it is over the spring retainer and  
release.  
5. Verify headlight aim.  
82  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Clutch System  
Periodically inspect the clutch sheaves for damage, wear, or belt  
residue. To maintain optimum performance, clean with non-oil based  
cleaners such as isopropyl alcohol.  
WARNING  
If you become aware of higher than normal clutch engagement or an  
unusual vibration or shift pattern, see your dealer immediately. Do not  
operate the machine until repairs have been made.  
All clutch maintenance and repairs must be performed by an authorized  
Polaris dealer. Any unauthorized modifications to clutches, such as  
adding or removing weights, will void the warranty.  
CAUTION  
The bushings in the weights and rollers of Polaris clutches are made of a  
material that may be damaged if lubricated. Do not lubricate clutch  
bushings.  
Clutch Alignment Offset  
Clutch alignment offset is important for maintaining optimum  
performance. See your dealer for service and adjustments. A special  
tool is required to check for proper alignment.  
Clutch Center Distance  
See your Owner’s Manual Supplement for recommended center  
distance for your machine. If adjustment is necessary, see your dealer.  
83  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Clutch System  
n Drive Belt Condition  
Periodically check the condition and tension of the drive belt, and  
always carry a spare belt. For improved drive-away during extremely  
cold temperatures, remove the belt and warm it to room temperature.  
Reinstall it before starting the snowmobile.  
Drive Belt Removal  
CAUTION  
Do not attempt to remove the drive belt after operating in reverse. The  
snowmobile must be stopped after forward motion to prevent damage to  
components during belt removal. Rotate the driven clutch  
counterclockwise 1/4 turn by hand to ensure forward engagement before  
attempting to remove the belt.  
1. Stop the engine after operating in a forward motion. Wait for the  
engine to come to a complete stop.  
2. Apply the brake (or lock the parking brake if equipped).  
3. Open the hood, remove the clutch guard retaining pin and open the  
clutch guard.  
4. Rotate the driven clutch counterclockwise 1/4 turn by hand to  
ensure forward engagement.  
5. Locate the L-wrench in the tool kit and install it into the open  
threaded hole in the outer sheave of the clutch. Rotate the wrench  
until the sheaves open far enough to remove the belt.  
Drive Belt Installation  
1. Drop the drive belt over the drive  
A
clutch and pull back the slack (A).  
NOTE:  
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 to tighten the sheaves. Remove the wrench  
and store in the tool kit.  
3. Close the clutch guard and reinstall the retaining pin.  
4. Close and secure the hood and release the parking brake.  
84  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Clutch System  
n Drive Belt Deflection  
A
B
C
Measure belt deflection with both  
clutches at rest and in their full  
neutral position.  
Place a straight edge on the belt (A)  
and apply downward pressure while  
measuring at point B. This  
measurement should be 1 1/4”.  
Drive Belt Adjustment  
1. Loosen the 7/6” jam nut on the belt width adjuster.  
2. Using a 1/8” Allen wrench, adjust the threaded set screw (C) as  
needed.  
NOTE:  
Turn the set screw in (clockwise) to increase the distance between  
the sheaves and out (counterclockwise) to decrease the distance.  
3. Tighten the jam nut.  
Clutch Center Distance  
See your Owner’s Manual Supplement for recommended center  
distance for your machine. If adjustment is necessary, see your dealer.  
Due to tolerances in belt length, it may be necessary for your dealer to  
make minor adjustments in the driven clutch to achieve correct belt  
tension.  
85  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Torque Stop  
If your snowmobile is equipped  
with an engine torque stop (1),  
periodically check torque stop  
clearance. With clutches in  
proper alignment, the torque stop  
clearance should be a minimum  
of .010to a maximum of .030″  
from the engine case (2). Adjust  
if necessary, and lock the jam  
nut.  
2
1
86  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Chain Tension  
Maintain the proper chain tension as outlined on page 76.  
Fall Tune-Up  
For maximum performance, arrange for a fall service tune-up with your  
Polaris dealer. His experienced and trained service technician will keep  
your machine in peak operating condition.  
Tool Kit  
A tool kit is included with each machine for emergency and routine  
maintenance. Always keep the tool kit with the snowmobile.  
NOTE:  
The tools and maintenance items mentioned in this book, as well as  
a long line of other Polaris accessories, are available at your Polaris  
dealer.  
87  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Track Maintenance  
WARNING  
Moving parts can cut and crush body parts. When performing the checks  
and adjustments recommended on the following pages, stay clear of all  
moving parts. Never perform track measurement or adjustments with the  
engine running.  
Track Tension  
Track adjustment is critical for proper handling. Always maintain  
correct tension and alignment.  
Tension adjustments should be made only after the track is warmed up  
and limber.  
1. Turn the machine off.  
2. Lift the rear of the machine and safely support it off the ground.  
3. Place the recommended weight or downward pressure on the track  
at the specified distance (see Track Tension Data below) ahead of  
the center of the rear idler wheel.  
NOTE:  
Measure at the point where the weight is hanging.  
4. Check for specified slack between the wear surface of the track clip  
and the plastic slider (C).  
If the track needs adjustment:  
Slider  
5. Loosen rear idler shaft bolt (D).  
6. Loosen locknuts (A).  
7. Tighten or loosen the  
track adjusting screws (B)  
as necessary to provide  
equal adjustment on both  
sides of the track.  
B
A
D
weight  
C
Track  
Track Tension Data  
Model  
Weight  
Measurement  
Location  
Measurement  
600 IQ Racer  
600RR  
10 lbs. (4.54 kg)  
10 lbs. (4.54 kg)  
16ahead of rear  
1 1/4 - 1 1/2”  
(3.2 - 3.8 cm)  
idler shaft  
16ahead of rear  
1 1/4 - 1 1/2”  
(3.2 - 3.8 cm)  
idler shaft  
88  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Track Maintenance  
If the track needs adjustment (continued):  
8. Repeat measurement on the other side of the track.  
NOTE:  
Check more frequently when machine is new.  
9. Start the machine and slowly rotate the track at least five  
revolutions. Let the track come to a stop (do not apply brakes).  
10. Check track alignment (see page 89) and adjust as necessary.  
11. Tighten locknuts (A).  
12. Tighten idler shaft bolts (D) and torque to 35 ft. lbs. (47.5 Nm).  
n Track Alignment  
Periodically check that the track is  
centered and running evenly on the  
slide rails. Misalignment will cause  
excessive wear to the track and slide  
rail.  
1. Safely support the rear of the  
machine with the track off the  
ground.  
2. Start the engine and apply a small  
amount of throttle until the track  
turns slowly at least five complete  
revolutions. Stop the engine and  
let the track come to a stop (do not  
apply brakes).  
A
3. Inspect track alignment by looking  
through the track window to make  
sure the rails (A) are evenly  
spaced on each side. If the track runs to the left, loosen left  
locknut and tighten the left adjusting bolt. If the track runs to the  
right, loosen right locknut and tighten the right adjusting bolt.  
4. After adjustments are complete, tighten locknuts and torque idler  
shaft bolts to 35 ft. lbs. (47.5 Nm).  
5. Repeat steps 2 and 3 to verify proper alignment.  
89  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Track Maintenance  
Track Inspection  
WARNING  
Broken track rods are a serious safety hazard. They can cause a rotating  
track to come off the machine, which could cause serious injury or death.  
Never operate with a damaged track. Never rotate a damaged track  
under power.  
2
Using a hoist, safely lift and support the  
rear of the snowmobile off the ground.  
Rotate the track by hand to check for  
possible damage.  
3
2
1
1
Carefully examine the track along the  
entire length of each rod, bending the  
track and inspecting for breakage. The  
three most common damage areas are  
shown in the illustration.  
Replace the track if any rod damage is  
found.  
Track Lubrication  
WARNING  
Operating with insufficient lubrication between the rail slide and track  
guide clips can cause track failure, loss of vehicle control and loss of  
braking ability, which can result in serious injury or death.  
Avoid operating for extended periods on ice and other surfaces that have  
little or no snow for lubrication.  
The slide rail requires adequate snow cover for sufficient lubrication.  
Excessive wear indicates insufficient lubrication. A new rail slide can  
cause faster heat build-up in limited lubrication, resulting in excessive  
wear.  
NOTE:  
If excessive slide wear occurs due to poor snow conditions,  
additional wheel kits are available. See your dealer for more  
information.  
NOTE:  
Track damage or failure caused by operation on ice or under other  
poor lubrication conditions will void the track warranty.  
90  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Steering System  
Steering Inspection and Adjustment  
Each week, or before a long ride, check all fasteners and tighten if  
necessary. Specifically check fasteners marked with a +.  
91  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Steering System  
Ski Alignment  
WARNING  
Improper ski alignment or adjustment may cause loss of steering control,  
resulting in serious injury or death. Do not attempt to change the ski  
alignment or camber adjustment. See your Polaris dealer.  
With the handlebars in a straight ahead position, and with vehicle  
weight compressing the suspension, measure from the straight edge of  
the skis at the center of the ski mounting bolt. The measurement  
between the skis at point X should be 1/8to 1/4greater than the  
measurement at point Y.  
NOTE:  
If the skis are misaligned, we recommend that your dealer correct  
the alignment, since camber adjustment may also be affected.  
92  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Steering System  
n 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 weekly to maintain positive steering characteristics. Skags  
must be replaced when worn to half their original diameter.  
NOTE:  
Carbide skags must be replaced if any abnormal wear or chipping is  
found.  
Skag Replacement  
1. Raise and support the front of the  
machine so the skis are  
approximately 6(15.2 cm) from  
the ground.  
2. Remove the attaching hardware  
and pry the skag (A) downward.  
3. Remove the forward portion of  
the skag.  
Reverse this procedure for new skag  
installation.  
93  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Suspension Maintenance  
n Rail Slide Wear  
Measure slide thickness at  
several points along the  
rail. Have your dealer  
replace the slide when it’s  
worn down to the top of  
the wear limit indicator  
groove (A). Do not operate the  
snowmobile if slide thickness  
measures less than 7/16″  
(1.1 cm).  
7/16  
(1.1 cm)  
A
n Pre-Ride Suspension Inspection  
Loose nuts and bolts can reduce your snowmobile’s reliability and  
cause needless repairs and down time. Before beginning any  
snowmobile trip, a visual inspection will uncover potential problems.  
Check the following items on a weekly basis or before any long trip:  
n Check rear idler wheel bolts for tightness.  
n Check rear idler adjusting bolt locknuts for tightness. See page 89  
for torque specs.  
n Check front torque arm limiter strap condition.  
n Check rail slide condition - have your dealer replace when worn to  
minimum thickness.  
n Check track tension (beginning on page 88).  
n Lubricate/grease all suspension components (see page 64).  
n Check ski runner/skag condition.  
94  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Extended Storage  
Off-season or extended storage of your snowmobile requires preventive  
measures to aid against deterioration and to prolong the useful life of  
many components.  
Cleaning and Preservation  
Proper storage starts with cleaning, washing, and waxing the hood,  
chassis, and plastic parts. Wipe down remaining surfaces with a damp  
cloth. Clean and touch up with paint any rusted or previously painted  
surfaces. Be sure that corrosive salt and acids are removed from  
surfaces before beginning preservation with waxes and rust inhibitors  
(grease, oil or paint).  
The machine should be stored in a dry garage or shed, out of direct  
sunlight, and covered with a fabric snowmobile cover. Plastic tarp may  
cause condensation to form and damage snowmobile components.  
Controls and Linkage  
All bushings, spindle shafts, tie rod ends, and cables should receive a  
light coat of oil or grease.  
Clutch and Drive System  
Remove the drive belt and store in a cool dry location. Lubricate the  
sheave faces of the drive and driven clutches with a light coat of oil or  
Polaris Cable Lubricant. See page 99 for part numbers. Do not  
lubricate clutch components, except the driven clutch shaft bushing as  
outlined in the Master Repair Manual. See your dealer.  
95  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Extended Storage  
Engine and Carburetor Protection  
Proper preparation of the engine and fuel system is vital to the  
prevention of rust and corrosion on precision engine parts during  
storage. Whenever the machine is stored for a period of more than 60  
days,the engine must be fogged with fogging oil. Follow the engine  
fogging instructions provided on the can. See page 99.  
Always add Premium Carbon Clean or a fuel conditioner/stabilizer to  
the fuel tank. See page 99 for the part numbers of Polaris products.  
Follow the instructions on the can, running the engine for five minutes  
to get additives through the entire fuel system. Top off with fresh fuel  
(premixed for 600 IQ Racer).  
If stabilizer is not used, drain the carburetors by removing the water  
trap drain plugs. See page 71.  
Using a fuel stabilizer and topping off the fuel tank eliminates the need  
to drain the fuel system. If you prefer to drain the fuel tank, use the  
following procedure.  
1. Transfer unused fuel from the fuel tank to an approved fuel  
container using a siphon pump. Do not re-use fuel after storage.  
2. Securely support the front of the snowmobile with a jack stand so  
the machine is elevated and the engine is tilted rearward.  
3. Remove the spark plug(s).  
4. Rotate the engine slowly, watching the piston until it’s at bottom  
dead center (BDC), the lowest position in the cylinder. On twin  
cylinder models, the opposite piston will be up.  
5. Pour approximately two ounces of Polaris injection oil into the  
spark plug hole.  
6. Wait one to two minutes and perform steps 3 to 5 on remaining  
cylinders.  
7. Replace the spark plugs and lower the machine to the floor.  
96  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Extended Storage  
Electrical Connections  
Separate electrical connector blocks and clean corrosive build-up from  
connectors. Lubricate or pack connector blocks with dielectric grease  
and re-connect. See page 99 for the part numbers of Polaris products.  
Replace worn or frayed electrical wire and connectors. Be sure wiring  
harness is properly secured away from sharp edges, steering linkage,  
moving parts, and hot exhaust parts.  
Track and Suspension  
Moderate track tension should be  
maintained during summer storage.  
The machine should be supported off  
the ground to allow the track to hang  
freely.  
97  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE  
Transporting the Snowmobile  
Whenever the snowmobile is transported:  
2
1. Turn the fuel valve  
clockwise to OFF to shut  
off the fuel supply (1).  
Turn the valve  
1
counter-clockwise to  
ON to turn the fuel  
supply on (2).  
NOTE:  
The fuel valve is  
located under the  
hood.  
2. Be sure the fuel cap is installed correctly.  
3. Always tie the snowmobile to the transporting unit securely  
using suitable straps.  
98  
Download from Www.Somanuals.com. All Manuals Search And Download.  
POLARIS PRODUCTS  
Part No.  
Description  
Engine Lubricants  
2870791  
2873023  
2871098  
2871097  
2871240  
2871721  
2871722  
2872347  
2874438  
2874439  
2874443  
Fogging Oil (12 oz. Aerosol)  
Synthetic 2-Cycle Racing Oil (gal.)  
Premium 2-Cycle Engine Oil (qt.)  
Premium 2-Cycle Engine Oil (gal.)  
Premium 2-Cycle Engine Oil (2.5 gal.)  
Premium Gold Synthetic 2-Cycle Engine Oil (qt.)  
Premium Gold Synthetic 2-Cycle Engine Oil (gal.)  
Premium Gold Synthetic 2-Cycle Engine Oil (2.5 gal.)  
VES II Synthetic 2-Cycle Engine Oil (qt.)  
VES II Synthetic 2-Cycle Engine Oil (gal.)  
VES II Synthetic 2-Cycle Engine Oil (2.5 gal.)  
Chaincase Lubricants  
2873105  
2872951  
Synthetic Chaincase Lubricant (qt.)  
Synthetic Chaincase Lubricant (12 oz.)  
Grease / Specialized Lubricants  
2871312  
2871322  
2871423  
2871329  
Grease Gun Kit, Premium All Season (3 oz.)  
Premium All Season Grease (3 oz. cartridge)  
Premium All Season Grease (14 oz. cartridge)  
Dielectric Grease (Nyogelt)  
Coolant  
2871323  
2871534  
Anitfreeze, 60/40 Premix (gal.)  
Anitfreeze, 60/40 Premix (qt.)  
Additives / Miscellaneous  
Carbon Clean Plus (12 oz.)  
Fuel Stabilizer (16 oz.)  
DOT 4 Brake Fluid (12 oz.)  
Engine Degreaser (12 oz.)  
Isopropyl  
2871326  
2870652  
2872189  
2872893  
2870505  
2872889  
2872890  
Brake and Clutch Cleaner  
Carb and Throttle Body Cleaner  
99  
Download from Www.Somanuals.com. All Manuals Search And Download.  
TROUBLESHOOTING  
Engine Troubleshooting  
CAUTION: Unless you have experience and training in two-cycle  
engine repair, see your dealer if technical problems arise.  
Problem  
Probable Cause  
Solution  
Erratic engine  
operating RPM  
during accelera-  
tion or load  
Drive clutch binding -Disassemble drive clutch to inspect shift  
weights for wear and free operation.  
SEE YOUR DEALER.  
-Clean and polish stationary shaft hub.  
Driven clutch  
variations  
malfunction  
-Replace ramp buttons and rollers.  
SEE YOUR DEALER.  
-Inspect movable sheaves for excessive  
bushing clearance and replace if necessary.  
SEE YOUR DEALER.  
-Replace drive belt.  
Harsh drive  
clutch  
Drive belt worn or  
too narrow  
engagement  
Excessive belt/sheave -SEE YOUR DEALER.  
clearance  
Drive belt turns Wrong belt for  
application  
-Replace drive belt.  
over  
Clutch alignment out -Adjust alignment offset.  
of spec  
Engine mount broken -Inspect and adjust or replace.  
or loose  
SEE YOUR DEALER.  
Machine fails to Clutch jammed  
move  
-Belt twisted, spring broken, weights stuck,  
lubricated. SEE YOUR DEALER.  
Track jammed  
-Foreign object caught or the rail slide  
melted to track clips due to lack of lubrica-  
tion.  
-Machine may be frozen to ground. Track  
may be iced up.  
Chaincase sprocket or  
chain jammed or bro- -Chain is loose or broken, chain tightener is  
ken loose. SEE YOUR DEALER.  
100  
Download from Www.Somanuals.com. All Manuals Search And Download.  
TROUBLESHOOTING  
Engine Troubleshooting  
Problem  
Probable Cause  
Solution  
Noise in drive  
system  
Broken drive clutch  
components  
-SEE YOUR DEALER.  
Bearing failure/  
-SEE YOUR DEALER.  
chaincase, jackshaft,  
or front drive shaft  
Drive belt surface flat  
spots  
-Inspect and replace if necessary.  
-Inspect and adjust or replace.  
-Inspect and replace if necessary.  
Drive chain loose or  
worn, sprocket teeth  
broken  
Poor low RPM Worn drive belt  
performance  
Excessive belt/sheave -SEE YOUR DEALER.  
clearance  
Loose torque stop  
Sticky clutch  
Seized engine  
-Inspect and adjust.  
-SEE YOUR DEALER.  
Engine doesn’t  
turn  
-SEE YOUR DEALER. Seizure is a result  
of poor lubrication, inadequate fuel supply,  
broken parts, or improper cooling.  
Hydrostatic lock  
-Fuel may have entered crankcase while  
vehicle was standing or being transported.  
SEE YOUR DEALER to correct cause.  
Drain plug(s) are located on lower crank-  
case for emergency draining.  
Engine requires Poor gasoline or not  
more than enough fuel getting to  
-Replace with fresh winter fuel.  
normal pulls to engine  
start  
101  
Download from Www.Somanuals.com. All Manuals Search And Download.  
TROUBLESHOOTING  
Engine Troubleshooting  
Problem  
Probable Cause  
Solution  
Engine turns  
but fails to start  
Faulty ignition  
-Remove spark plug(s) and replace with  
new plug(s). If engine still fails to start,  
check for spark; if no spark SEE YOUR  
DEALER.  
No fuel to engine  
-Make sure the fuel valve is “ON”. Check  
tank level and fill up with correct fuel.  
-Ice in fuel line, filter, or pump. On the  
standard Polaris carburetor, the choke will  
not function with the throttle depressed.  
See second item under “Probable Cause” of  
“Engine continually backfires”.  
Flooded engine (nor-  
mal situation caused  
by too much chok-  
ing)  
-Hold throttle open, crank engine several  
times (may be necessary to change plug(s),  
however, the plug(s) may operate satisfac-  
torily when dried).  
Poor engine compres-  
sion  
-Running too lean a mixture (too small a  
main jet will cause seizure resulting in loss  
of power). SEE YOUR DEALER. This  
indicates a major engine problem that must  
be repaired before engine is run.  
Engine lacks  
power  
Fouled or defective  
spark plug  
-Change and test operation.  
Fuel filter (loss of  
high RPM power)  
-Check fuel filter flow. Disconnect hose  
and drain about 1/2 cup. Fuel flow should  
be steady and encompass the entire diame-  
ter of fuel line. If not, replace filter.  
Incorrect clutching  
-SEE YOUR DEALER.  
Carburetor and fuel  
pump  
-There’s no adjustment to change power  
output. SEE YOUR DEALER.  
Engine  
continually  
backfires  
Faulty plug(s)  
Carburetor  
-Change plug(s)  
-Dirt or ice in fuel system. (Deicer should  
be added to non-ethanol fuel at all times for  
assurance against fuel line icing.)  
102  
Download from Www.Somanuals.com. All Manuals Search And Download.  
TROUBLESHOOTING  
Suspension Troubleshooting  
Problem  
Solution (perform only one change at a time)  
Rear suspension  
-Increase torsion spring preload  
-Increase rear shock compression damping by turning screw  
bottoms too easily  
clockwise  
-Increase torsion spring wire diameter (see your dealer)  
Rides too stiff in  
rear  
-Check for binding suspension shafts and grease all pivot points  
-Decrease torsion spring preload adjustments  
-Decrease rear shock compression valving by turning screw  
counterclockwise (if equipped with optional Indy Select shock)  
-Change to lighter valving if (if equipped with Foxshocks)  
-Check for proper track tension  
Machine darts from -Make sure skis are aligned properly  
side to side  
-Make sure spindles and all steering components are free turning  
-Make sure skags are straight on skis  
-Check rail slide and replace if worn  
-Reduce ski pressure:  
SReduce IFS spring preload  
SReduce rear torsion spring preload  
Front end pushes  
Steering is heavy  
-Check for worn skags  
-Check for binding suspension shafts and grease all pivot points  
-Increase IFS spring preload by adjusting cam or threaded ad-  
juster  
-Decrease front limiter strap length  
-Check ski alignment  
-Check skags and skis for damage  
-Reduce ski pressure:  
SIncrease front track spring preload  
SReduce IFS spring preload by adjusting cam  
SReduce rear torsion spring preload  
Setting up for deep -Change worn rail slide  
snow operation -Move front track shock assembly to upper position  
103  
Download from Www.Somanuals.com. All Manuals Search And Download.  
TROUBLESHOOTING  
Belt Troubleshooting  
Belt Wear/Burn  
Belt Wear/Burn Diagnosis  
Causes  
Solutions  
Driving at low RPM  
Drive at higher RPMs. Gear the machine down. Check belt  
deflection.  
Insufficient warm-up  
Towing at low RPM  
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.  
Do not tow in deep snow. Use fast, aggressive throttle to  
engage clutch.  
Riding with high RPM Lower the gear ratio. Remove windage plates from the  
and slow speed (8000  
clutch. Reduce RPM. Avoid riding in high ambient  
RPM/10 MPH)  
temperatures.  
Ice and snow build-up  
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 carb and choke synchronization, fouled plugs,  
debris in the carbs, and water, ice, or dirt in gas tank or fuel  
line.  
Loading machines onto Skis may gouge into trailers and prevent the drivetrain from  
trailers  
spinning properly. Use enough speed to drive the machine  
completely onto the trailer. Push and pull it to finish  
loading if necessary.  
Clutch malfunction  
Inspect clutch components. See your dealer.  
Use fast, aggressive throttle to engage clutch.  
Slow, easy clutch en-  
gagement  
104  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WARRANTY  
Service And Warranty Information  
Obtaining Service and Warranty Assistance  
Read and understand the service data and the Polaris warranty  
information contained in this manual. Contact your Polaris dealer for  
replacement parts, service or warranty. Your dealer receives frequent  
updates on changes, modifications and tips on snowmobile  
maintenance, which may supersede information contained in this  
manual. Your dealer is also familiar with Polaris policies and  
procedures and will be happy to assist you.  
When contacting us about parts, service, or warranty, always provide  
the following information:  
1. Serial number 5. Details of trouble experienced  
2. Model number 6. Length of time and conditions of operation  
3. Dealer name  
7. Previous correspondence  
4. Date of purchase  
Use the page provided near the front of your Owner’s Manual to record  
the identification numbers of your snowmobile and its engine.  
Polaris Customer Service  
United States: 1-888-704-5290  
Canada: 1-204-925-7100  
Polaris Anti-Theft System  
The Polaris anti-theft system (PATS) monitoring program is designed  
to aid owners of registered snowmobiles in recovery of stolen  
machines.  
Administration  
1. Polaris snowmobile owner reports theft.  
A. In addition to notifying the proper law enforcement offi-  
cials, the owner must call Polaris Customer Service.  
B. Owners must provide their name, address, telephone num-  
ber and the model and serial number of stolen machines.  
2. Polaris warranty will provide all dealerships with a monthly  
updated list of all stolen units to further monitor thefts.  
3. Polaris warranty will aid in notifying the proper owner when a unit  
is recovered.  
105  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WARRANTY  
Limited Warranty  
Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM-  
ITED WARRANTY on all components of the Polaris snowmobile against defects in  
material or workmanship. This warranty covers the parts and labor charges for repair or  
replacement of defective parts that are covered by this warranty. The warranty begins on  
the date of purchase. This warranty is transferrable to another consumer, during the war-  
ranty period, through a Polaris dealer.  
Registration  
At the time of sale, the Warranty Registration Form must be completed by your dealer  
and submitted to Polaris within ten days. Upon receipt of this registration, Polaris will  
record the registration for warranty. No verification of registration will be sent to the  
purchaser as the copy of the Warranty Registration Form will be the warranty entitle-  
ment. If you have not signed the original registration and received the customer copy,  
please contact your dealer immediately. NO WARRANTY COVERAGE WILL BE  
ALLOWED UNLESS THE SNOWMOBILE IS REGISTERED WITH POLARIS.  
Initial dealer preparation and setup of your snowmobile is very important in ensuring  
trouble-free operation. Purchasing a snowmobile in the crate or without proper dealer  
setup will void your warranty coverage.  
Warranty Coverage and Exclusions  
Limitations of warranties and remedies  
This warranty excludes any failures not caused by a defect in material or workmanship.  
The warranty does not cover accidental damage, normal wear and tear, abuse or improper  
handling. The warranty also does not cover any snowmobile that has been structurally  
altered, neglected, improperly maintained, used for racing or used for purposes other  
than for which it was manufactured. The warranty does not cover any damages that oc-  
cur during trailer transit or as a result of unauthorized service or parts. In addition, this  
warranty does not cover physical damage to paint or finish, stress cracks, tearing or punc-  
turing of upholstery material, corrosion or defects in parts, components or the snowmo-  
bile due to fire, explosions or any other cause beyond Polaris’ control.  
This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that  
are not compatible with the snowmobile.  
The exclusive remedy for breach of this warranty shall be, at Polaris’ exclusive option,  
repair or replacement of any defective materials, or components or products. THE REM-  
EDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAIL-  
ABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL  
HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL  
OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF  
EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEG-  
LIGENCE, OR OTHER TORT OR OTHERWISE. Some states do not permit the exclu-  
sion or limitation of incidental or consequential damages or implied warranties, so the  
above limitations or exclusions may not apply to you if inconsistent with controlling  
state law.  
106  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WARRANTY  
Limitations of warranties and remedies  
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IM-  
PLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICU-  
LAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE YEAR  
WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS WAR-  
RANTIES NOT STATED IN THIS WARRANTY. Some states do not allow limitations  
on how long an implied warranty lasts, so the above limitation may not apply to you if  
inconsistent with controlling state law.  
How to Obtain Warranty Service  
If your snowmobile requires warranty service, you must take it to a Polaris dealer autho-  
rized to repair Polaris snowmobiles. When requesting warranty service you must present  
your copy of the Warranty Registration form to the dealer. (The cost of transportation to  
and from the dealer is YOUR responsibility). Polaris recommends that you use your  
original selling dealer; however, you may use any Polaris Servicing Dealer to perform  
warranty service.  
Please work with your dealer to resolve any warranty issues. Your dealer will contact the  
appropriate 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  
recommend the use of Polaris engine oil.  
2. Damage resulting from the use of non-recommended lubricants may not be covered  
by warranty.  
107  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WARRANTY  
Conditions and Exclusions  
In order to qualify for warranty, the product must have been properly set up and tested by  
a Polaris Dealer (if applicable). Failure of any dealer to perform the required vehicle Pre-  
Delivery Inspection, perform all applicable service bulletins and have the consumer sign  
the pre-delivery inspection (PDI) form prior to delivery may void the warranty. Failure to  
provide proof of required periodic maintenance upon request may result in denial of  
warranty coverage. Use of the recommended Polaris products for lubrication and mainte-  
nance as directed by the Owner’s manual is highly recommended. Should a failure occur  
during the warranty period resulting from the use of non-recommended products, war-  
ranty coverage may be denied.  
Warranty does not apply to parts exposed to friction surfaces, stresses, environmental  
conditions and/or contamination. The following items are excluded from warranty con-  
sideration if the failure was due to wear or not the direct result of a defect:  
Skis  
Tracks  
Ski wear rods  
Slide rails  
Suspension components  
Brake components  
Seat components  
Clutches and components  
Steering components  
Batteries  
Finished and unfinished surfaces  
Carburetor/Throttle body components  
Engine components  
Drive belts  
Hydraulic components  
Circuit breakers/Fuses  
Electronic components  
Light bulbs/Sealed beam lamps  
Idler wheels  
Warranty applies to the product only and does not allow for coverage of personal loss.  
Some items are considered “consumable,” meaning they are considered part of normal  
maintenance or part of completing an effective repair. The following items are excluded  
from warranty coverage in the event of a warranty claim:  
Spark Plugs  
Filters  
Lubricants such as oil, grease, etc.  
Batteries (unless defective)  
Cosmetic damage/repair  
Coolants  
Fuel  
Sealants  
Hotel fees  
Towing charges  
Mileage  
Meals  
Shipping/ handling fees  
Product pick-up/delivery  
Rentals/Loss of product use Loss of vacation/personal time  
This warranty also excludes failures resulting from improper lubrication; improper en-  
gine timing; improper fuel; surface imperfections caused by external stress, heat, cold or  
contamination; operator error or abuse; improper component alignment, tension, adjust-  
ment or altitude compensation; failure due to snow, water, dirt or other foreign substance  
ingestion/contamination; improper maintenance; modified components; use of aftermar-  
ket components resulting in failure; unauthorized repairs; repairs made after the warranty  
period expires or by an unauthorized repair center; use of the product in competition or  
for commercial purposes. Warranty will not apply to any product which has been dam-  
aged by abuse, accident, fire or any other casualty not determined a defect of materials or  
workmanship.  
108  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WARRANTY  
Polaris Second Year Engine Service Contract  
Second Year Engine Service Contract is standard on all eligible new and unused  
snowmobiles that were Snow Checked through an authorized Polaris dealer during the  
March/April Snow Check promotion. The free Second Year Engine Service Contract is  
honored by all authorized Polaris snowmobile dealers in North America and is  
transferable 120 days after the original purchase date, free of charge, through any Polaris  
snowmobile dealer. Coverage on Snow Check units is automatic. Although you do not  
receive a warranty card, your dealership should have printed a copy of the warranty  
registration form. This form is your proof of warranty.  
Consumer Exclusions  
S
Each repair visit after the first twelve months of standard warranty coverage is subject  
to a $50 deductible.  
S
The free Second Year Engine Service Contract applies to the first 5,000 miles or two  
(2) calendar years from date of purchase, whichever comes first. Tampering with the  
odometer shall void all warranties/service contracts. No extensions to coverage under  
this engine service contract can be given. Used snowmobiles are not eligible under  
this program.  
S
Snowmobiles used for commercial purposes or for racing are excluded from cover-  
age.  
Coverage  
Coverage for second year engine failures due to defects in materials and workmanship  
will be determined by Polaris in its sole discretion. Coverage is automatic with no  
additional paperwork required. The free Second Year Engine Service Contract is subject  
to a $50 deductible per visit. Regular, documented service maintenance visits are  
required to validate this warranty.  
A partial list of items excluded from coverage includes:  
S
S
S
S
S
Damage due to accident, fire, explosion, theft, or other causes beyond Polaris’ control.  
Damage caused by the failure of other components of the snowmobile.  
Failures caused by improper fuel or oil.  
Piston seizures, unless caused by a defective engine component.  
Failures caused due to improper adjustments.  
S
S
Failure due to unauthorized service.  
Failures due to lack of service as required in the owner’s manual or Polaris updates.  
This includes off-season storage as listed in the owner’s manual.  
S
S
Failure due to use of unauthorized parts or modifications.  
Normal wear parts, including but not limited to spark plugs, hoses, batteries, controls,  
and recoil ropes are excluded from coverage. Gaskets are covered, as are intake and  
exhaust manifolds excluding paint coverage.  
S
S
Electrical coverage is limited to the ECU box, coils, stator plate, and sensors. Wiring  
and other electrical components are excluded from coverage.  
Cooling system coverage is limited to the water pump assembly and components, fan,  
fan bearings, temperature sensor, gasket and seals.  
S
S
Non wear related throttle body parts are covered. The fuel pump is covered.  
Clutches and related clutch parts, including but not limited to, the drive belt, are ex-  
cluded from coverage.  
S
S
Electrical components are excluded from coverage.  
Gearcases and transmissions are excluded from coverage.  
109  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WARRANTY  
Exported Vehicles  
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-  
RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD  
OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCA-  
TION.  
This policy does not apply to vehicles that have received authorization for export from  
Polaris Industries. Dealers may not give authorization for export. You should consult an  
authorized dealer to determine this vehicle’s warranty or service bulletin coverage if you  
have any questions.  
This policy does not apply to vehicles registered to government officials or military per-  
sonnel on assignment outside the country of the selling dealer’s authorized location.  
This policy does not apply to Safety Recalls.  
How to Get Service  
In the Country where your vehicle was purchased:  
Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you  
move or are traveling within the country where your vehicle was purchased, Warranty or  
Service Bulletin repairs may be requested from any authorized Polaris dealer who sells  
the same line as your vehicle.  
Outside the Country where your vehicle was purchased:  
If you are traveling temporarily outside the country where your vehicle was purchased,  
you should take your vehicle to an authorized Polaris dealer. You must show the dealer  
photo identification from the country of the selling dealer’s authorized location as proof  
of residence. Upon residence verification, the servicing dealer will be authorized to per-  
form the warranty repair.  
If You Move:  
If you move to another country, be sure to contact Polaris Customer Assistance and the  
customs department of the destination country before you move. Vehicles importation  
rules vary considerably from country to country. You may be required to present docu-  
mentation of your move to Polaris Industries in order to continue your warranty cover-  
age. You may also be required to obtain documentation from Polaris Industries in order  
to register your vehicle in your new country.  
If Purchased From A Private Party:  
If you purchase a Polaris product from a private citizen outside of the country in which  
the vehicle was originally purchased, all warranty coverage will be denied.  
Notice  
If your vehicle is registered outside of the country where it was purchased, and you have  
not followed the procedure set out above, your vehicle will no longer be eligible for war-  
ranty or service bulletin coverage of any kind. (Vehicles registered to Government offi-  
cials or military personnel on assignment outside of the country where the vehicle was  
purchased will continue to be covered by the basic warranty.)  
For questions call Polaris Customer Assistance (see page 105).  
110  
Download from Www.Somanuals.com. All Manuals Search And Download.  
WARRANTY  
Snowmobile Engine Emissions Limited Warranty  
This snowmobile engine emissions limited warranty is in addition to the Polaris standard  
limited warranty for snowmobiles.  
Polaris Industries Inc. warrants that the new engine, including all parts of its emission-  
control system, is designed, built and equipped so it conforms to current U.S. Environ-  
mental Protection Agency regulations applicable to snowmobile emissions under 40  
CFR1051, 1065 and 1068 at the time of sale to the ultimate purchaser. Polaris warrants  
that the engine is free from defects in materials and workmanship that may keep it from  
meeting these regulations.  
The warranty period for this emissions certified snowmobile engine starts on the date  
when the engine is first purchased and continues for 4000 kilometers (2485 miles) of  
vehicle travel, 200 hours of operation, or 30 calendar months, whichever comes first.  
This engine emissions limited warranty covers the parts and labor charges for repair or  
replacement of defective parts that are covered by this warranty. This includes compo-  
nents whose failure increases the snowmobile engine’s emissions. To the extent they are  
present on your snowmobile engine, this includes electronic controls, fuel injection com-  
ponents, exhaust gas recirculation system components, and aftertreatment system compo-  
nents. Replacing or repairing other components not covered by this warranty is the  
responsibility of the snowmobile owner.  
The exclusive remedy for breach of this limited warranty shall be, at the exclusive option  
of Polaris, repair or replacement of any defective materials, components or products.  
THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE ONLY  
REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY.  
POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL,  
CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,WHETHER  
ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CON-  
TRACT, NEGLIGENCE OR OTHER TORT OR OTHERWISE. ALL IMPLIED WAR-  
RANTIES (INCLUDING BUT NOT LIMITED TO ANY IMPLIED WARRANTIES  
OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE) ARE  
LIMITED IN DURATION TO THE WARRANTY PERIOD DESCRIBED HEREIN.  
POLARIS DISCLAIMS ALL EXPRESS WARRANTIES NOT STATED IN THIS  
WARRANTY.  
Some states do not allow limitations on how long an implied warranty lasts, so the above  
limitation may not apply if it is inconsistent with the controlling state law. This limited  
warranty excludes failures not caused by a defect in material or workmanship. This limit-  
ed warranty does not cover damage due to accidents, abuse or improper handling, main-  
tenance or use. This limited warranty also does not cover any engine that has been  
structurally altered. This limited warranty also does not cover physical damage, corrosion  
or defects caused by fire, explosions or other similar causes beyond the control of Polar-  
is.  
Owners are responsible for performing the scheduled maintenance identified in the own-  
er’s manual. Polaris can deny an emissions warranty claim if any specified critical emis-  
sions-related maintenance is not performed. Performance of other scheduled maintenance  
is strongly recommended, but is not necessary to keep the emissions-related warranty  
valid. Any qualified repair shop or qualified person may maintain, replace, or repair the  
emission control devices or systems on your snowmobile. Polaris recommends that you  
contact an authorized Polaris dealer to perform any service that may be necessary.  
It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts  
manufacturer reduces the effectiveness of the vehicle’s emission controls. Tampering  
with emission controls is prohibited by federal law and may result in civil penalties.  
111  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE RECORD  
DATE  
MILES/KM  
TECHNICIAN  
SERVICE PERFORMED / COMMENTS  
150 mi.  
(240 km)  
500 mi.  
(800 km)  
1000 mi.  
(1600 km)  
2000 mi.  
(3200 km)  
112  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE RECORD  
DATE  
MILES/KM  
TECHNICIAN  
SERVICE PERFORMED / COMMENTS  
113  
Download from Www.Somanuals.com. All Manuals Search And Download.  
MAINTENANCE RECORD  
DATE  
MILES/KM  
TECHNICIAN  
SERVICE PERFORMED / COMMENTS  
114  
Download from Www.Somanuals.com. All Manuals Search And Download.  
INDEX  
A
D
Accessories . . . . . . . . . . . . . . . . . . 40-43  
Altitude Ignition Setting . . . . . . . . . . 29  
Avalanches . . . . . . . . . . . . . . . . . . . . 13  
Driver Awareness . . . . . . . . . . . . . . . 11  
Driving Downhill . . . . . . . . . . . . . . . 14  
Driving in Hilly Terrain . . . . . . . . . . 15  
Driving on Slippery Surfaces . . . . . . 14  
Driving Responsibly . . . . . . . . . . . . . 18  
B
Before Starting the Engine . . . . . . 45-48  
Belt Troubleshooting . . . . . . . . . . . 104  
Bleeding the Cooling System . 67, 74-75  
Bleeding the Brake System . . . . . . . . 80  
Brake Components . . . . . . . . . . . . . . 78  
Brake Fluid . . . . . . . . . . . . . . . . . . . . 79  
Brake Lever Travel . . . . . . . . . . . 46, 78  
Brake, Parking . . . . . . . . . . . . . . . . . 47  
Brakes . . . . . . . . . . . . . . . . . . . . . . 78-80  
Brakes, Hydraulic . . . . . . . . . . . . . . . 46  
E
Electrical Connections . . . . . . . . . . . 97  
Emergency Stopping . . . . . . . . . . . . . 57  
Engine and Carburetor Protection . . 96  
Engine Break-In . . . . . . . . . . . . . . 50-52  
Engine Safety . . . . . . . . . . . . . . . . . . 10  
Engine Service Contract . . . . . . . . . 109  
Engine Stop Switch . . . . . . . . . . 49, 57  
Engine Troubleshooting . . . . . . 100-102  
Engine Warm-Up . . . . . . . . . . . . . . . 54  
Excessive Speed . . . . . . . . . . . . . . . . 14  
Exhaust System . . . . . . . . . . . . . . . . . 72  
C
Carburetion . . . . . . . . . . . . . . . . . . . . 56  
Carburetor . . . . . . . . . . . . . . . . . . . . . 71  
Carburetor Adjustments . . . . . . . . . . 71  
Chain Tension . . . . . . . . . . . . . . . . . . 87  
Chaincase Oil Level . . . . . . . . . . . . . 66  
Choke and Cable . . . . . . . . . . . . . . . . 65  
Cleaning and Preservation . . . . . . . . . 95  
Clutch Alignment . . . . . . . . . . . . . . . 83  
Clutch and Drive System . . . . . . . . . 95  
Clutch Center Distance . . . . . . . . 83, 85  
Clutch Cover Warning . . . . . . . . . . . 20  
Clutch System . . . . . . . . . . . . . . . . 83-85  
Clutches . . . . . . . . . . . . . . . . . . . . . . 16  
Cold Weather Drive-Away . . . . . . . . 16  
Controls and Linkage . . . . . . . . . . . . 95  
Coolant Level . . . . . . . . . . . . . . . . . . 73  
Coolant Mixture . . . . . . . . . . . . . . . . 73  
Cooling . . . . . . . . . . . . . . . . . . . . . 72-75  
F
Fall Tune-Up . . . . . . . . . . . . . . . . . . . 87  
Flushing the Cooling System . . . . . . 74  
Front Rear Scissor Stop . . . . . . . . . . . 36  
Front Springs . . . . . . . . . . . . . . . . . . 33  
Fuel Filter . . . . . . . . . . . . . . . . . . . . . 70  
Fuel Lines . . . . . . . . . . . . . . . . . . . . . 70  
Fuel Premix . . . . . . . . . . . . . . . . . . . 51  
Fuel Pump . . . . . . . . . . . . . . . . . . . . 70  
Fuel Recommendations . . . . . . . . . 51-52  
Fuel System Deicers . . . . . . . . . . . . . 51  
H
Halogen Bulbs . . . . . . . . . . . . . . . . . 82  
Handlebar Adjustments . . . . . . . . . . . 39  
Handlebar with Riser Block . . . . . . . 39  
Headlight Adjustment . . . . . . . . . . . . 81  
Headlights . . . . . . . . . . . . . . . . . . . 81-82  
High Temperature Indicator . . . . . . . 73  
Hydraulic Brake Inspection . . . . . . . . 77  
D
Daily Storage . . . . . . . . . . . . . . . . . . 58  
Disabled Operators . . . . . . . . . . . . . . 12  
DRAGON Ignition System . . . . . . 26-27  
DRAGON Mode Facts . . . . . . . . . . . 26  
DRAGON Mode Operation . . . . . . . 27  
Drive Belt . . . . . . . . . . . . . . . . . . . . . 16  
Drive Belt Adjustment . . . . . . . . . . . 85  
Drive Belt Condition . . . . . . . . . . . . . 84  
Drive Belt Deflection . . . . . . . . . . . . 85  
Drive Belt Installation . . . . . . . . . . . . 84  
Drive Belt Removal . . . . . . . . . . . . . 84  
Drive Chain Tension . . . . . . . . . . . . . 76  
I
Ice and Snow Build-up . . . . . . . . . . . 13  
IFS . . . . . . . . . . . . . . . . . . . . . . . . . . 30  
IFS Adjustment Options . . . . . . . . . . 30  
IFS Components . . . . . . . . . . . . . . . . 30  
Inadequate Snow Conditions . . . . . . 17  
Independent Front Suspension . . . . . 30  
Intake Filter . . . . . . . . . . . . . . . . . . . . 69  
Intake Silencer . . . . . . . . . . . . . . . . . 16  
115  
Download from Www.Somanuals.com. All Manuals Search And Download.  
INDEX  
J
S
Jetting Guidelines . . . . . . . . . . . . . . . 56  
Spark Plugs . . . . . . . . . . . . . . . . . . 67-68  
Start the Engine and Check . . . . . . . . 49  
Starting a Cold Engine . . . . . . . . . . . 53  
Starting a Warm Engine . . . . . . . . . . 53  
Starting the Engine . . . . . . . . . . . . . . 53  
Steering Adjustment . . . . . . . . . . . . . 91  
Steering Inspection . . . . . . . . . . . . . . 91  
Steering System . . . . . . . . . . . 48, 91-93  
Stopping . . . . . . . . . . . . . . . . . . . . . . 57  
Storage . . . . . . . . . . . . . . . . . . 58, 95-97  
Storage . . . . . . . . . . . . . . . . . . . . . . . 96  
Survival Preparation . . . . . . . . . . . . . 12  
Suspension . . . . . . . . . . . . . . . . . . . . 97  
Suspension Coupling . . . . . . . . . . . . 36  
Suspension Maintenance . . . . . . . . . . 94  
Suspension Performance Tips . . . . . . 34  
Suspension Troubleshooting . . . . . . 103  
Suspension, Front . . . . . . . . . . . . . 30-33  
Suspension, Rear . . . . . . . . . . . . . . 34-38  
L
Lighting Check . . . . . . . . . . . . . . . . . 49  
Lubrication . . . . . . . . . . . . . . . . . . 64-66  
M
Maintenance Interval Table . . . . . . 61-63  
Maintenance Program . . . . . . . . . . . . 60  
Maneuverability . . . . . . . . . . . . . . . . 16  
O
Oil Filter . . . . . . . . . . . . . . . . . . . . . . 69  
Oil Level, Injection (600RR) . . . . . . 55  
Oil Lines . . . . . . . . . . . . . . . . . . . . . . 69  
Oil Recommendations . . . . . . . . . . . . 50  
Operating Area . . . . . . . . . . . . . . . . . 49  
Operation Warning . . . . . . . . . . . . 22-23  
Operator Safety . . . . . . . . . . . . . . . . 7-19  
P
Symbols . . . . . . . . . . . . . . . . . . . . . . .  
7
Passenger Warning . . . . . . . . . . . . . . 21  
Polaris Products . . . . . . . . . . . . . . . . 99  
Pre-Ride Checklist . . . . . . . . . . . . . . 44  
Pre-Ride Suspension Inspection . . . . 94  
Pressure Cap Warning . . . . . . . . . . . . 20  
T
Tether Switch . . . . . . . . . . . . . . . . . . 49  
Throttle Cable . . . . . . . . . . . . . . . . . . 65  
Tool Kit . . . . . . . . . . . . . . . . . . . . . . . 87  
Torque Stop . . . . . . . . . . . . . . . . . . . 86  
Torsion Spring Tension . . . . . . . . . . . 35  
Towing . . . . . . . . . . . . . . . . . . . . . . . 58  
Track . . . . . . . . . . . . . . . . . . . . . . . . . 97  
Track Alignment . . . . . . . . . . . . . . . . 89  
Track Cooling . . . . . . . . . . . . . . . . . . 55  
Track Inspection . . . . . . . . . . . . . 48, 90  
Track Lubrication . . . . . . . . . . . . . . . 90  
Track Maintenance . . . . . . . . . . . . 88-90  
Track Safety . . . . . . . . . . . . . . . . . . . 10  
Track Tension . . . . . . . . . . . . . . . . . . 88  
Track Tension Data . . . . . . . . . . . . . . 88  
Track Warm-Up . . . . . . . . . . . . . . . . 54  
Track Warning . . . . . . . . . . . . . . . . . 21  
Traction Products . . . . . . . . . . . . . . . 41  
Transporting the Snowmobile . . . . . . 98  
R
Rail Slide Wear . . . . . . . . . . . . . . . . . 94  
Rear Rear Scissor Stop . . . . . . . . . . . 37  
Recommended Maintenance Program 60  
Reverse . . . . . . . . . . . . . . . . . . . . . 28-29  
Reverse Kit Maintenance . . . . . . . . . 29  
Reverse Warning . . . . . . . . . . . . . . . . 20  
Rider Capacity . . . . . . . . . . . . . . . . . 12  
Riding Apparel . . . . . . . . . . . . . . . . . .  
Riding Position . . . . . . . . . . . . . . . . . 10  
9
S
Safety Decals and Locations . . . . . 20-23  
Scissor Stop . . . . . . . . . . . . . . . . . 36-37  
Service and Warranty Information . . 105  
Shock Absorber Components . . . . . . 31  
Shock Damping . . . . . . . . . . . . . . . . 32  
Shock Spring Preload, Front . . . . . . . 32  
Shock Valving . . . . . . . . . . . . . . . . . . 33  
V
Variable Exhaust System . . . . . . . . . . 70  
Vehicle Identification Numbers . . . . . .  
6
Signal words . . . . . . . . . . . . . . . . . . . .  
7
W
Skag Replacement . . . . . . . . . . . . . . . 93  
Ski Alignment . . . . . . . . . . . . . . . . . . 92  
Ski Skags . . . . . . . . . . . . . . . . . . . . . 93  
Slide Rail and Track Cooling . . . . . . 55  
Warning Labels . . . . . . . . . . . . . . . 20-23  
Wear Strips . . . . . . . . . . . . . . . . . . . . 43  
Weight Transfer During Acceleration 38  
Windchill/Temperature Charts . . . . . . 19  
116  
Download from Www.Somanuals.com. All Manuals Search And Download.  

Peavey Musical Instrument Amplifier KB A 60 User Manual
Peavey Speaker 210HP User Manual
Peavey Stereo Equalizer CEQ 280 User Manual
Philips Stereo Receiver US2 PH61150 User Manual
Philips Switch UM10011 User Manual
Philips Toaster L1700 User Manual
Philips Universal Remote SBC RU 120 User Manual
Planet Technology Network Card WGSW 2403 User Manual
Plustek Scanner SmartOffice User Manual
Poulan Trimmer 952711879 User Manual