Instruction/ maintenance manual of the product 600 HO IQ CFI Polaris
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WARNING Read, understand, and follow all of the in structions and safe ty precautions in this manual and on all produ ct labels. F ailure to follow the safety precautions could result in serious injury or death .
1 WELCOME Thank you for purcha sing a Polaris vehicle, and welcome to our world- wide family of Polaris enthusiasts. Be sure to visit us online at www .polarisindustries.com for the la test news, new product introduc- tions, upcoming events, car eer opportunities and more.
2 POLARIS and POLARIS TH E W A Y OU T are regist ered trademarks of Pola ris Indus- tries Inc. RIDER SELECT is a trademark of Polaris Industries Inc. Copyright 2005 Polaris Sales Inc. All inform ation contained within this publication is based on the latest product information at th e time of publication.
3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 This section contains helpful info rmation fo r owners and drivers and illustrates the location of important identification numbers that should be recorded in the owner's manual.
4 INTRODUCTION V ehicle Identification Numbers Record your snowmo bile's identification numbers and k ey number in the spaces provided. Remove the spare key and store it in a safe place. Y our key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced.
5 INTRODUCTION Preservation of the Environment Polaris is committed to supporting an environmental education cam- paign. W e encourage governments to adopt rigorous safety training pro - grams that encourage protection of ou r environment, including wildlife and vegetation.
6 SAFETY Operator Safety The following signal words and symbol s appear throughout this man ual and on your vehicle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety ale rt symbol , on your vehicle or in thi s manual, alerts you to the potential for injury .
7 SAFETY Operator Safety Follow the recommended mainte nance program begi nning on page 90 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your d ealer at specific mileage intervals. W ARNING Driving a snowmobile requires your full attenti on.
8 SAFETY Operator Safety Stay Clear of T rack Y our snowmobile is propelled by a revo lving track that must be partially exposed for proper operation. Stay Clear of Engine Never attempt adjustments with the en gine running .
9 SAFETY Operator Safety Riding Apparel Be prepared, be warm and b e com- fortable when riding. Be aware of the weather forecast, especially the windchill, and dress accordingly . See the chart on page 20. Helmet W earing a helmet can prevent a sever e head injury .
10 SAFETY Operator Safety Disabled Operators Safe operation of this rider -active vehi cle requires good judgement and physical skills. Operators with cognitiv e or physical disabilities have an increased risk of loss of control, wh ich could result in serious injury or death.
11 SAFETY Operator Safety Rider Capacity Driving 1-Up - Some Polaris snowmobiles are designed for a single rider only . A decal on the console of these mode ls indicates single rider operation. Driving 2-Up - Some Polaris snowmobiles are designed for up to two riders.
12 SAFETY Operator Safety Driver Awareness Slow down when traveling near poles, posts, or other obstacles. Be especially alert if you're snow mobiling after dark. Always be on the alert for wire fences. Single strands are especially dangerous, since there may be a great distance between posts.
13 SAFETY Operator Safety Avalanches Snowmobilers should always be prop erly trained and equipped before traveling in mountainous terrain: • T ake an av alanche cl ass • T ravel with experienced people • T ravel on designated trails • Make sure each person is equipped with a shovel, probe and avalanche beacon.
14 SAFETY Operator Safety Ice and Snow Build-up Before driving, manually tu rn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If dif ficulty is encountered, remove ice and snow build-up that may be obstru cting the steering linkage.
15 SAFETY Operator Safety Driving Downhill When riding downhill, shift your weig ht to the rear of the machine and reduce your speed to a minimum. Appl y just enough throttle to keep the clutch engaged, allow ing the engine 's compression to help slow the machine and keep it fro m rolling freely downhill.
16 SAFETY Operator Safety Driving in Hilly T errain Use extra caution when operating in hilly terrain. If climbing a hill is unavoidable, keep your weight low and forward. If you mu st cross the face of a slope, keep your weight on the uphill side of the machine to maintain proper balance and av oid possible roll-over .
17 SAFETY Operator Safety Drive Belt Do not operate the engine wi th the drive belt removed. Any servicing that requires op eration 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.
18 SAFETY Operator Safety Inadequate Snow Conditions Since snow provides the only lubrica tion for the power slide suspension and, on liquid cooled models, coo ling for the engine, adequate snow cover is a requirement for operation of your machine.
19 SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently , and even the most docile condi- tions may become dangerous if oper ators drive improperly . If you 're new to snowmobiling, acquaint your self with the machine and with what it will and won't do under va rious conditions.
20 SAFETY Operator Safety Windchill/T emperature Charts The following informatio n is provided to help you d etermine when tem- peratures becom e da ngerous for riding.
21 SAFETY Safety Decals and Locations W arning decals hav e been placed on the snowmobile for you r protec- tion. Read and follow the instructions of the deca ls and other warnings on the snowmobile carefully .
22 SAFETY Safety Decals and Locations T rack W arning The track warning decal is on the rear of the tunnel: Stay clear of track. Do not sit on seat back.
23 SAFETY Safety Decals and Locations Reverse Warning The reverse warning decal is located on the console, either below the windshield or beside the steering pos t: WARNING Revers e operation, even at low speeds, can ca use loss of control resulting in serious injury or death.
24 SAFETY Safety Decals and Locations Operation W arning • T o avoid serious injury or death, read and unde rstand all warnings and the Owner's Manual before oper ation. If manual is missing, con- tact a Polaris dealer for a replac ement. • This vehicle is capable of high speeds.
25 FEA TURES 5 11 2 3 4 10 9 13 14 15 1 12 8 7 6 16 17 18 19 1. Hood 2. Headlight 3. Windshield 4. Handlebar 5. Op erator Seat 6. Sea t Storage Compartment 7. T aillights 8. Rea r Bumper 9. Snow Flap 10. Suspension 11. T rack 12. Console Storage Com part- ment (if equipped) 13.
26 FEA TURES 1. F uel Filler Cap 2. RIDER SELECT (if equipped ) 3. Ignition Switch 4. Br ake Lever 5. Headlight Adjuster 6. MFD Gauge 7. Engine Stop Switch 8. Throttle Control 9. Hood Hold Down Straps 10. Recoil Starter Handle 11. Ch oke Lever 12. Parking Brake 13.
27 FEA TURES RIDER SELECT Adjusta ble Steering System The RIDER SELECT adjustable steering system (if equipped) allows you to adjust the handlebar position to fit your style of riding. Some models have five (5) adjustment positions. Other models have seven (7) positions.
28 FEA TURES RIDER SELECT Adjusta ble Steering System 1. S top the snowmobile. 2. Press the release button and move the handlebar forward or rearward to the desired position. W ARNING Attempting to adjust the handlebar positi on while the snowmobile is moving could result in loss of control and serious injury or death.
29 FEA TURES Cargo Rack If equipped, the maximum weight capacity for the cargo rack is 15 lbs. (7 kg). Always secure car go before operating. Do not exceed the rack weight limit.
30 FEA TURES Seat Storage Compartments Open or close the stor- age compartment with the key , or lift the seat lever and lift the seat to access the under- seat storage area. On T ouring models, the passenger seat and car go bag are removable to provide open storage for transporting larger items.
31 FEA TURES Detonation Elimination T echnology (DET) The DET system prevents damage to the engine from deton ation by automatically reducing the engine tim ing and adding fuel whenever the sensors detect detonation.
32 FEA TURES Instrumentation MFD Component Identification Digital Display Identification Item 1 Analog (if equipp ed) 2 Digital Gauge 3 CHECK ENGINE Indicator (carb models) 4 Low Oil Indicator 5 High .
33 FEA TURES Instrumentation MFD Settings W ith the engine running, use the MFD Control Switch to set the MFD display to your preference. The rocker switch ( 9 ) has a MODE but- ton (top) and a SET button (bottom). Standard vs. Metric The MFD will display either stan- dard or metric units of measurement.
34 FEA TURES Instrumentation MFD Digital Display Programs Press the MODE button to cycle thro ugh the three MFD programs: Per- formance, Engine and History .
35 FEA TURES Instrumentation MFD Digital Display Programs T rip Settings Tr i p 1 a n d Tr i p 2 a r e odometers used to check fuel mileage or to keep track of distance traveled. 1. T o reset a trip odometer to zero, enter the T rip 1 or T rip 2 display .
36 FEA TURES Instrumentation MFD Digital Display Programs Pe rformance Program Clock Setting 1. While in the CLOCK display , press and hold the SET button for five seconds. 2. When the hour starts flashing press the SET switch once to advance one hour , or press and hold the SET button to advance the hour once every 0.
37 FEA TURES Instrumentation MFD Digital Display Programs Engine Prog ram The Engine Program automatically di splays the engine coolant tempera- ture, engine hours, electrical system voltage level and fuel level (if equipped).
38 FEA TURES Instrumentation MFD Digital Display Programs Engine Prog ram Altitude (if equipped) The rider can calibrate th e altimeter for current atmospheric conditions .
39 FEA TURES Instrumentation MFD Digital Display Programs History Program The History Program automatically di splays electrical system voltage level and fuel level (if equipped). While in the History mode, press the SET button to view maximum vehicle speed, maximum engi ne rpm or the current service interval set- ting.
40 FEA TURES Instrumentation MFD Digital Display Programs Service Interval Reminder The gauge logs the number of engine hours between service reminders. When the logged hours reaches the designated service interval (set by the user), the gaug e provides a re minder that service is due.
41 FEA TURES Instrumentation MFD Battery Replacement (models with clocks) If the clock function of th e MFD isn't working properly , replace the battery . Replacement batteries are available from your dealer . 1. Remove the plenu m from the under- side of the hoo d.
42 FEA TURES Instrumentation MFD Battery Replacement (models with clocks) 6. Install a new battery with fingers only . 7. Seal the end of the battery compar tm ent using high strength double- sided tape between the two compar t ment halves or high strength single-sided tape around the outside of the compartment.
43 THE PERFECT FIT F ront Suspension Adjustments Independent F ront Suspension (IFS) Break in the suspension for about 150 miles (240 km) before making any fine-tuning adjustme nts. Settings will vary from rider to rider , depending on rider weight, vehicle speed, riding style, and trail cond itions.
44 THE PERFECT FIT F ront Suspension Adjustments Shock Spring Preload Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-to-ground pres- sure. When adjusting, be sure the springs on both the l eft and right sides of the machine are at the same adjustment.
45 THE PERFECT FIT F ront Suspension Adjustments Shock V alving Some shocks can be revalved if spri ng preload alone isn't suff icient and further adjustment is desired to control suspension stiffness. Please see your Polaris dealer. Shock Compres sion Damping T urn the adjustment knob (or screw) to make adjustments to the compression damping.
46 THE PERFECT FIT Rear Suspension Adjustments Rider weight, riding style, trail co nditions, and vehicle speed all af fect suspension action. Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions.
47 THE PERFECT FIT Rear Suspension Adjustments Suspension Performance Tips • Rider weight usually determines th e position at which the spring pre- load should be set. However , this ma y vary with riding style. W ith a little experimentation, each rider can find a preferred se tup.
48 THE PERFECT FIT Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) T o set up the rear suspension tor- sion spring preload, measure the distance between the ground and rear bumper . This is measurement X. T ake the first measurement with no rider and with the rear suspension at full extension.
49 THE PERFECT FIT Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) T o determine sag, common ly referred to as ride-in, subtract measure- ment Y from X (sag=X-Y). If the measu red sag is incorrect, adjust the FRA position and/or rear torsion spring preload.
50 THE PERFECT FIT IQ Rear Suspensi on Adjustments T orsion Spring Preload T o adjust rear torsion spring preloa d, rotate the three-position cam using the engine spark p lug tool. Adjust ment is easiest when the cam is rotated from low to medium, and then to high.
51 THE PERFECT FIT IQ Rear Suspensi on Adjustments Rear Shock Compression Damping (Pre mium Shocks) T urn the adjustment kn ob on the shock reservoir to make adjustments to the compression damping. Positions are labeled on the shock. When adjusting, we recommend that you turn the adjuster slightly , then test ride.
52 THE PERFECT FIT IQ Rear Suspensi on Adjustments Suspension Coupling On all Polaris snowmobile rear suspens ions, there are two torque arms that control the mo vement of the rail beam. Pr ior to the advent of sus- pension coupling, thes e torque arms could mo ve independently of each other .
53 THE PERFECT FIT IQ Rear Suspensi on Adjustments Rear T o F ront Coupling and the Rear Rear Scissor Stop (RRS S) The rear rear scissor stop (RRSS) couples the movement of the rear torque arm with the front torque ar m and limits the am ou nt of indepen- dent movement be tween the rear torque and the front torque arm.
54 THE PERFECT FIT IQ Rear Suspensi on Adjustments W eight T ransfer During Acceleration The preferred method for control- ling weight transfer during accel- eration is by adjusting the rear rear scissor stop (RRSS). The factory setting is the best for most trai l riding conditions.
55 THE PERFECT FIT SwitchBack Rear Suspension Adjustments T orsion Spring Preload T o adjust rear torsion spring preloa d, rotate the three-position cam using the engine spark plug tool. Different rate torsion springs are available if a firmer ride is desired.
56 THE PERFECT FIT SwitchBack Rear Suspension Adjustments Rear Shock Compression D amping T urn the adjustment knob on the shock reservoir to make adjustments to the compression damping. Positions are labeled on the shock. When adjusting, we recommend that you turn the adjuster slightly , then test ride.
57 THE PERFECT FIT F AST M-10 Rear Su spension Adjustments The M-10 suspension has been design ed to be very sensitive to rider weight. Changes in rider weigh t of 25 lbs.
58 THE PERFECT FIT F AST M-10 Rear Su spension Adjustments M-10 Static Sag and Ride Height Settings FRA Position The FRA setting is the primary rear su spension adjustment . It will have the most effect on the rear suspension performance. T o adjust the FRA: 1.
59 THE PERFECT FIT F AST M-10 Rear Su spension Adjustments M-10 Static Sag and Ride Height Settings Rear Spring Preload If FRA position alone does not allow the setup of the pro per amount of sag, the center retainer of the rear track shock can be repla ced with optional retainers to adjust the prel oad and change the sag.
60 THE PERFECT FIT F AST M-10 Rear Su spension Adjustments Ski Pressure Ski pressure is set at the factory to deliver the optimum balance be tween ride and handling. If a rider prefer s more ski pressure for improved steering performance, adjustments can be made to the front limite r strap and front arm mount.
61 THE PERFECT FIT F AST M-10 Rear Su spension Adjustments Ski Pressure NOTE: By design, the BIASED COUPLE design of the M-10 suspen- sion displaces the rear ar m as the front arm is compressed.
62 THE PERFECT FIT Handlebar Adjustments When making handleb ar adjustments, always be sure the handlebars, brake lever and throttle lever operat e smoothly and do not contact the fuel tank, windsh ield or any other part of the vehicle when t he handle- bars are turned fully to the left or right.
63 THE PERFECT FIT Handlebar Adjustments Handlebar Position If your snowmobile is equipped with the RIDER SELECT feature, adjust handlebar positio n as outlined on page 27. For models with sta- tionary steering posts, adjust ha ndlebar position as outlined below .
64 THE PERFECT FIT P assenger Grab Handle Adjustment On some T ouring models the position of the passenger grab handles can be adjusted for rider preference.
65 THE PERFECT FIT Accessories Polaris offers a wide range of accesso ries for your snowmobile to help make each ride more enjoyable. Use only Polaris parts and accessories on your Polaris snowmobile.
66 THE PERFECT FIT T raction Products Studs Before equipping your machine with traction products, be aware of the laws in your area pertaining to the use of traction products.
67 THE PERFECT FIT T raction Products n Carbide Skags A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmob ile and t o prevent ski wear caused by contact with roads and other bare terrain. Use carbide skags with studded tracks to help maintain prop er vehicle steering and control.
68 PRE-RIDE INSPECTIONS Pre-Ride Checklist Inspect all items on th e checklist for proper operation or condition before each use of the snowmobile. Pr ocedures are outlined on the refer- enced pages. Look for a checkmark ( n ) on the referenced pages to locate the pre-ride inspection items.
69 PRE-RIDE INSPECTIONS Before Starting the Engine Read and Understan d Y our Owner's Manual Read the Owner's Manual completely and refer to it often. The manual is your guide to safe and enjo yable snowmobiling experience. n Throttle Lever The throttle and brake are the primar y controls of your snowmobile.
70 PRE-RIDE INSPECTIONS Before Starting the Engine n Brakes Always check the following items fo r proper operation before starting the engine. Brake Lever T ravel Squeeze the brake lever . It should move no closer to the handgrip than 1/2 I (1.3 cm). A smaller distance indicates low brake fluid leve l or air in the hydraulic system.
71 PRE-RIDE INSPECTIONS Before Starting the Engine n P arking Brake Lever Lock Use the parking brake lever lock onl y when you want the machine to remain stationary; for ex ample, when parked on an incline for a period of five minutes or less. 1. Brake Lever 2.
72 PRE-RIDE INSPECTIONS Before Starting the Engine n Steering System Before driving, manually tu rn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If dif ficulty is encountered, remove ice and snow build-up that may be obstru cting the steering linkage.
73 PRE-RIDE INSPECTIONS Before Starting the Engine n Hood Latches The hood of the snowmobile pr otects the operator from moving parts as well as aiding in sound emission con trol and other functions. Under no circumstances should your snowmobile be operated with the hood open or removed.
74 PRE-RIDE INSPECTIONS Start the Engine and Check n Engine S top Switch Check the auxiliary shut-of f switch for proper operation. Push the switch down to stop the engine . Pull it up to allow restarting. n Ignition Switch Make sure the engine st ops when the ignition switch is turned to OFF .
75 OPERA TION Starting the Engine 1. T urn the key to the ON position. 2. Pull the engine stop switc h up to the RUN posi tion. 3. If equipped with electric start, turn the key to ST AR T to crank the engine. Release the key to the ON position when the engine starts.
76 OPERA TION 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. Premix the first tank of fuel with on e pint of Polaris injection o il for each five gal- lons of fuel.
77 OPERA TION Engine Break-In Oil Injection System Always check and fill the oil tank when refueling. See page 81. Oil Recommendations This snowmobile is equipped with a variab le exhaust system (V ES). Engine lubrication comes from oil ad ded to the fuel and oil injection systems.
78 OPERA TION T rack W arm-Up Follow these steps to ensure proper warm-up of the engine, drive train and track. 1. Use an appropriate stand to securely sup- port the rear of the snowmobile at the rear bumper . The track should be about 4 I (10 cm) off the ground.
79 OPERA TION Fu e l W ARNING Gasoline is highl y flammable and explosive under certain condition s. • Always exercise extreme caution w henever handling gasoli ne. • Always refuel outdoors or in a well-ventilated area. • Always turn off the engine before refueling.
80 OPERA TION Fu e l For peak performance, Polaris recomm ends the use of 91 oc tane or higher fuel. Although 87 octane fuel is usable, some engine perfor- mance will be lost and fuel econ omy will decrease. Do not use lower than 87 octane fuel. Do not use fuel containing mor e than 10% ethanol (including E85) .
81 OPERA TION Oil n Low Oil Indicator Light The low oil indicator light will alert th e operator if the oil level is low . V isually check for oil in the bottle. Add oil before further operation of the snowmobile. See page 77 for oi l recommendations.
82 OPERA TION n Engine Stop Switch Push down on the engine stop switch ( 9 ) to ground out the ig nition and stop the engine quickly . Pull the switch up to the ON position to allow restarting.
83 OPERA TION Throttle Lever If the engine stops abruptly when the throttle lever is released: 1. T urn the ignition switch to OF F . 2. V isually inspect the throttle cabl e and carburetor/throttle body to determine what caused the safety switch to activate.
84 OPERA TION Emergency Stoppi ng The following chart lists methods for stopping the snowmobile in the event of an emergency . See page 82 for more information about the engine stop switch and throttle safety switch.
85 OPERA TION Emergency Starting If the recoil starter system fails, an em ergency start strap is provided in the tool kit. 1. Open the hood. 2. Remove the left side panel. 3. Using the belt removal tool, follow the directions on the air box to relieve belt tension.
86 OPERA TION Electronic Reverse (PERC t ) Electronic reverse will activate only if the engine RPM is below 4000. Engaging Reverse 1. S top the snowmobile and leave the engine idling. 2. Make sure the area behind your vehicle is clear . 3. Push the yellow reverse button on the left-hand control for one sec- ond, then release.
87 OPERA TION Daily Storage At the end of each ride, park the snowmo- bile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4 I (10 cm) off the ground. Remove the key and cover the machine.
88 MAINTENANCE Emission Control Information Any qualified repair shop or qualifie d person may maintain, replace, or repair the emission control devices or systems on your snowmobile.
89 MAINTENANCE Emission Control Information Owner's Responsibilities Please read the Snowmobile Engine Emissions Limited W arranty on page 145, and read th e maintenance section of your o wner's manual.
90 MAINTENANCE P olaris Recommended Maintena nce Program T o ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform se rvice checks as out- lined in this manual. Record maintenance and service in the Mainte- nance Log beginning on page 147.
91 MAINTENANCE P eriodic Maintenance Interval T able The following chart is a guide based on average riding conditions. Y ou may need to increase frequency based on ri ding conditions. When inspection reveals the need for replacement parts, always use genuine Polaris parts, available from your Polaris dealer .
92 MAINTENANCE P eriodic Maintenance Interval T able Item See Pag e Frequency 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi. (3200 km) Pre- Season BRAKES Hose Routing -- II II Hose Cond.
93 MAINTENANCE P eriodic Maintenance Interval T able I - Inspect (clean, adjust, tighten, lubricate, replace if necessary) C - Clean R - Replace L - Lubricate Item See Pag e Fr eq u e n c y 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi.
94 MAINTENANCE Lubrication F ront Suspension Lubricate the steering post U-joint with engine fogging oil at th e intervals outlined in the maintenance charts beginning on page 90. Lubricate the U-joint after seasonal storage as well as before seasonal storage.
95 MAINTENANCE Lubrication Rear Suspension SwitchBack Rear Suspension M-10 128 Rear Suspen sion M-10 136 Rear Suspen sion 9 9 9 9 9 9 9 9 9 9 9 9 9.
96 MAINTENANCE Lubrication Driveshaft Bearing Inject grease into the fitting on the speedometer sensor housing until grease purges from the seal on the inside of the tunnel. This should take approximately two pump s. Do not use more t han four pumps. Throttle Cable Lubricate the throttle cable lightly with grease or oil.
97 MAINTENANCE Lubrication n Chaincase Oil Check the chaincase oil level a t the intervals outlined in the maintenance charts beginning on page 90. The sigh t glass (1) is located on the lower rear of the chaincase. Maintain the oil level at or slightly below the center of the sight glass (2).
98 MAINTENANCE Lubrication Chaincase Oil Oil Change 1. Position the vehicle on a level surface. 2. Remove the drain plug (4) and drain the oil into a drain pan. Allow the oil to drain completely . 3. Clean off all metal shavings from the plug. 4. Install a new sealing washer on the drain plug.
99 MAINTENANCE Spark Plugs A new engine can cause temporary spar k plug fouling due to the preser- vative added during the assembly p rocess. A void prolonged idle speeds, which cause plug fouling and carbonization. Refer to your Owner's Manual Supplement for the specific spa rk plug to be used in your machine.
100 MAINTENANCE Spark Plug Condition Spark plug condition is indicative of engine operation. The spark plug firing end condition s hould be read after the engine has been warmed up and the vehicle has been driven at higher spe eds. Immediately check the spark plug for correct color .
101 MAINTENANCE Spark Plug Removal and Replacement 1. Remove the spark plug cap. 2. Using the special wrench provided in the tool pouch, rota te the spark plug counterclockwise to remove. 3. Reverse the proced ure for spark plug installation. 4. T orque to 18-22 ft .
102 MAINTENANCE Intake Filters The intake foam filters limit snow ingestion into the intake system. When operating in loose powd er snow , check the foam fil- ters periodically to remove any accumulation of snow . Fu e l P u m p All fuel pump service must be pe rformed by an authorized Polaris dealer .
103 MAINTENANCE Cooling System Coolant The coolant supplied in the system at the factory is a 50/50 mixture of ethylene-glycol and distilled water , which will provide adequate freeze protection under most conditions. If the vehicle will be stored or oper- ated at extremely low te mperatures , greater protectio n may be required.
104 MAINTENANCE Cooling System Coolant High T emperat ure Indicator Light The high temperature indicator light wi ll illuminate when engine cool- ant temperature becomes too hot for safe continued operation of the engine.
105 MAINTENANCE Cooling System Bleeding the Cooling System Use of a non-standard pressure cap will not allow the recovery system to function properly . If the pressure cap needs replacement, contact your dealer for the correct part. Perform the blee ding procedure when the engine is cold.
106 MAINTENANCE Exhaust System Check the exhaust system for wear or damage at approx imately 2000 miles (3200 km). Always allow the en gin e and exhaust system to cool completely before inspecting. 1. Open the hood and inspect the mu ffler and pipes for cracks or dam- age.
107 MAINTENANCE Brakes Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 70. Brake pads must be replaced when the brake pad material becomes thin- ner than the backing pl ate (approximately 1/16 I ).
108 MAINTENANCE Brakes Brake Fluid The brake fluid level can be seen through a plastic sight glass in the brake reservoir . If the fluid is suffic ient, the sight glass will be black. If the sight glass is any color other than black, add brake fluid. Replace brake fluid at least every two years with Polaris DOT 4 high temperature brake fluid.
109 MAINTENANCE Brakes Bleeding the Hydraulic Brake System Air in the hydraulic brak e system will cause spon gy brake lever action. Bleed the system before operating the snowmobile. During the bleeding proc edure, keep the brake handle as level as possi- ble.
110 MAINTENANCE Lights NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causin g a hot spot that will shorten the life of the lamp. If fingers do touch the bu lb, clean it with an alcohol- moistened towel. Headlight Bulb Removal 1.
111 MAINTENANCE Lights T aillight/Brakelight Replacement 600 HO IQ CFI/60 0 HO IQ LX CFI 1. Open the rear storage compart- ment. 2. Reach into the compartme nt and locate the socket assembly above the door opening . 3. T urn the socket counterclo ckwise 1/4 turn.
112 MAINTENANCE Clutch System Periodically inspect clutch sheaves for damage, wear or belt residue. T o maintain optimum performance, clean with non-oil based cleaners such as isopropyl alcohol. Clutch Alignment Offset Clutch alignment offset i s import ant for maintaining optimum perfor- mance.
113 MAINTENANCE Clutch System Drive Belt Belt width and length must match the center distance of the clutches and sheave width of the drive clutch. Pola ris recommends the use of O.E.M. belts. Other belts may match the dime nsions, but can drastically change the shift pattern, resulting in poor performance.
114 MAINTENANCE Clutch System Drive Belt Removal 1. S top the engine after operat- ing in a forward motion. 2. T urn the ignit ion key off. W ait for the engine to come to a complete stop. 3. Lock th e parking brake. 4. Open the hood and rem ove the left side panel.
115 MAINTENANCE Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. NOTE: T o ensure s atisfactory belt life, install belts so they operate in th e same direction of rotation by positioning the identifica- tion numbers so that you can read them.
116 MAINTENANCE Clutch Systematics n Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge (1) on the belt and apply downward pressure while measuring at point 2. This measurement should b e 1 1/4 I (3.
117 MAINTENANCE Clutch System To r q u e S t o p Periodically check torque stop cleara nce. W ith clutches in proper align- ment, measure rear torque stop clea rance from the engine case. Measure front torque stop clearance from the bracket when the isolator is bot- tomed out on th e bracket.
118 MAINTENANCE F all T une-Up For maximum performance, arrange for a fall service tune-up with your Polaris dealer . His experienced and tr ained service technician will keep your machine in peak oper ating condition. T rack Maintenance T rack Inspection 1.
119 MAINTENANCE T rack Maintenance T rack Lubrication The slide rail needs snow for lubrication. Excessive wear indicate s insufficient lubrication. A new rail slide can cause faster heat build-up in limited lubrication, resulting in excessive wear .
120 MAINTENANCE T rack Maintenance T rack T ension T rack adjustment is critical for prop er handling. Always maintain cor- rect tension and alignment. NOTE: T ension adjustments should be ma de only after the track is warmed up and lim ber . 1. T urn the engine off.
121 MAINTENANCE T rack Maintenance T rack T ension 4. Check for specified slack between th e wear surface of the track clip and the plastic slider . Refer to the T rack T ension Data Chart on page 120. If the track needs adjustment: 5. Loosen the rear idler shaft bolt.
122 MAINTENANCE T rack Maintenance n T rack Alignment Periodically check that the track is centered and runnin g evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. 1. Safely support the rear of the ma chine with the track off the ground.
123 MAINTENANCE Steering System Steering Inspection and Adjustment Each week, or before a long ride, ch eck all steering system fasteners and tighten if necessary .
124 MAINTENANCE Steering System Ski Alignment W ith the handlebars in a st raight ahead position, and with vehi cle weight compressing the suspension, measure from the straight e dge of the skis at the center of the sk i mounting bolt.
125 MAINTENANCE Steering System n Ski Skags Check skags before each use of the snowmobile to ensu re positive steer- ing characteristics. Skags must be replaced when worn to half their orig- inal diameter . NOTE: Carbide skags must b e replaced if any abno rmal wear o r chip- ping is found.
126 MAINTENANCE Steering System 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 ( 9 ). Do not operate the snowmobile if slide thickness measures les s than 7/16 I (1.
127 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 componen ts.
128 MAINTENANCE Extended Storage Bearings Grease the jacks haft and drive sha ft clutch side bearings w ith Polaris Premium All-Season Grease or a simi lar high quality grease to prevent corrosion. Clutch and Drive System Remove the drive belt and store in a cool dry location.
129 MAINTENANCE Extended Storage Electrical Connections Replace worn or frayed electrical wi re and connec tors. Be sure wiring harness is properly secured away from sha rp edges, steering linkage, moving parts, and hot exhaust pa rts. T ransporting the Snowmobile Whenever the snowmobile is transported: 1.
130 POL ARIS PRODUCTS Pa r t N o . Description Engine Lubrica nts 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2-Cycle Engine Oil (qt.) 2871097 Premium 2-Cycle Engine Oil (gal.) 2871240 Premium 2-Cycle Engine Oil (2.5 gal.) 2871721 Premium Gold Synthetic 2-Cycle Engine Oil (qt.
131 TROUBLESHOOTING Engine T roubleshooting Unless you have experience and traini ng in two-cycle engine repair , see your dealer if tec hnical problems arise. Problem Probable Ca use Solution Erratic engine oper- ating RPM during acceleration o r load variations Drive clutch binding • SEE YOUR DEALER.
132 TROUBLESHOOTING Engine T roubleshooting Problem Probable Ca use Solution Noise in drive sys- tem Broken drive clutch components • SEE YOUR DEALER. Bearing failure/ chaincase, jack shaft, or front drive shaft • SEE YOUR DEALER. Drive belt surface flat spots • Inspect and replace as needed.
133 TROUBLESHOOTING Engine T roubleshooting Problem Probable Ca use Solution Engine turns but fails to start Faulty ignition • Install new spark plug(s). If engine still fails to start, check for spark. If there's no spark, SEE YOUR DEALER. No fuel to engine • Make sure the fuel valve is on.
134 TROUBLESHOOTING IQ Suspension T roubleshooting Problem Solution Rear suspension bot- toms too easily • Adjust torsion spring preload to achieve proper static sag (see page 48). • Change torsion spring to stif fer optional spring (see your dealer).
135 TROUBLESHOOTING M-10 Suspension T roubleshooting Problem Solution Rear suspension bot- toms too easily • Increase FRA position (see setup decal under hood for ini- tial po sition.) • Install appropriate optional ce nter retainer on rear track shock (see page 59).
136 TROUBLESHOOTING SwitchBack Suspension T roubleshooting Problem Solution Rear suspension bot- toms too easily • Set static sag (see page 48). Adjust torsion spring blocks or install optional torsion spri ngs to achieve correct sag. • Increase shock co mpressi on damping (see page 51).
137 TROUBLESHOOTING Drive Belt T roubleshooting Belt W ear/Burn Diagnosis Causes Solutions Driving at low RPM • Drive at higher RPMs. Gear the machine down. Check belt deflection. Insufficient warm-up • W arm the engine at least five minutes. T ake the drive belt off the ma chine in extremely cold weather and warm it up.
138 W ARRANTY Service and W arranty Information Obtaining Service and W arranty Assistance Read and understand the service data an d the Polari s warranty information con- tained in this manual. Cont act your Polaris dealer for replacement parts, service or warranty .
139 WA RRANTY Service and W arranty Information Polaris Anti- Theft System The Polaris anti-theft system (P A TS) monito ring program is designed to aid owners of registered snowmobiles in recovery of stolen machines. Administration 1. Polaris snowmobile owner reports theft.
140 W ARRANTY Limited W arranty Polaris Sales Inc., 2100 Highway 55, Me dina, MN 55340, provides a ONE YEAR LIM- ITED W ARRANTY on all components of the Po laris snowmobile ag ainst defects in material or workmans hip. This warranty covers the parts and labor charges for repair or replacement of d efective parts that are cove red by this warranty .
141 WA RRANTY Limitations of warranti es and remedies ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W A RRANTIES OF MERCHANT ABILITY AND FITNESS FOR A P AR- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE ONE YEAR W ARRANTY PERIOD.
142 W ARRANTY Conditions and Exclusion s In order to qualify for warranty , the product must have been properly set up and tested by a Polaris Dealer (if applicable).
143 WA RRANTY Polaris Second Y ear Engine Service Contract Second Y e ar Engine Service C ontract is standard on all el igible new and unused snow- mobiles that were Snow Checked through an authorized Polaris dealer during the March/April Snow Check promot ion.
144 W ARRANTY Exported V ehicles EXCEP T WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER'S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that have received authorization for export from Polaris Industries.
145 WA RRANTY Snowmobile Engine Emis sions Limited W arranty This snowmobile engine emi ssions limited warranty is in addition to the Polaris stan- dard limited warrant y for sn owmobiles.
146 W ARRANTY Snowmobile Engine Emis sions Limited W arranty Some states do not allow lim itations on how long an implied warranty lasts, so the above limitation may not appl y if it is inconsistent with the controlling state la w . This limited warranty excludes failures not ca used by a defect in material or workmanship.
147 MAINTENANCE L OG Present this section of your manual to your dealer each time your snow- mobile is serviced. This will provide you and future owners wit h an accurate log of maintenance and servi ces performed on the snow mobile. DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 150 mi.
148 MAINTENANCE L OG DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS.
149 MAINTENANCE L OG DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS.
150 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 65 Adjustabl e Headlights . . . . . . . . . . . 30 Adjustable Steering System . . . . 27, 28 Air Pollution . . . . . . . . . . . . . . . . . . . 5 Avalanches . . . . . . . . . . . . . . . .
151 INDEX L Lever, Seat La tch . . . . . . . . . . . . . . . 30 Lights . . . . . . . . . . . . . . . . . . . 110, 111 Limiter Strap Posi tion, SwitchBack . 55 Low Oil In dicator Light . . . . . . . . . . 81 Lubrication . . . . . . . . . . . . . . . . .
152 INDEX T Taillight/Brakelight Replacement . 111 Throttle Cable . . . . . . . . . . . . . . . . . 96 Throttle Lever . . . . . . . . . . . . . . 69, 83 Throttle Safety Switch . . . . . . . . 69, 82 Torque Stop . . . . . . . . . . . . . . . . . . 117 Torsion Spring Preload, IQ .
An important point after buying a device Polaris 600 HO IQ CFI (or even before the purchase) is to read its user manual. We should do this for several simple reasons:
If you have not bought Polaris 600 HO IQ CFI yet, this is a good time to familiarize yourself with the basic data on the product. First of all view first pages of the manual, you can find above. You should find there the most important technical data Polaris 600 HO IQ CFI - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Polaris 600 HO IQ CFI you will learn all the available features of the product, as well as information on its operation. The information that you get Polaris 600 HO IQ CFI will certainly help you make a decision on the purchase.
If you already are a holder of Polaris 600 HO IQ CFI, but have not read the manual yet, you should do it for the reasons described above. You will learn then if you properly used the available features, and whether you have not made any mistakes, which can shorten the lifetime Polaris 600 HO IQ CFI.
However, one of the most important roles played by the user manual is to help in solving problems with Polaris 600 HO IQ CFI. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Polaris 600 HO IQ CFI along with tips on how to solve them. Even if you fail to solve the problem, the manual will show you a further procedure – contact to the customer service center or the nearest service center
