Instruction/ maintenance manual of the product 600 IQ ES 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 dea th.
1 WELCOME Thank you for purchasin g 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. Copyright 2009 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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 This section contains helpful info rmation for own ers and drivers and illustrates the location of important identification numbers that should be recorded in the owner's manual.
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5 INTRODUCTION Important Notes for Owners and Drivers After reading this manual, store it in the snowmobile for convenient ref- erence. It should remain with the snowmobile when th e snowmobile is sold. Some of the illustrations and photos used in this manual are general rep- resentations.
6 INTRODUCTION Preservation of the Environment Polaris is committed to supporting an environmental education cam- paign. W e encourage state and provin cial governments across the sn ow- belt to adopt rigorous safety traini ng programs that encourage protection of our environment, includ ing wildlife and vegetation.
7 INTRODUCTION V ehicle Identification Numbers Record your snowmobile 's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. 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.
8 SAFETY Operator Safety The following signal words and symbol s appear throughout th is manual 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 alert symb ol indicates a potential personal injury ha zard.
9 SAFETY Operator Safety Follow the recommended mainte nance program beginn ing on page 79 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your d ealer at specific mileage intervals. Driving a snowmobile requires your full atten tion.
10 SAFETY Operator Safety Stay Clear of T rack Y our snowmobile is propelled by a revo lving track that must be part ially exposed for proper operation. W ARNING! 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.
11 SAFETY Operator Safety Riding Apparel Be prepared, be warm and be com- fortable when riding. Be aware of the weather forecast, especially the windchill, and dress accordingly . See the chart on page 22. W ARNING! A void wearin g loose clothing or long scarves, which can become entangled in moving parts and cause serious injury .
12 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.
13 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.
14 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.
15 SAFETY Operator Safety Avalanches Snowmobilers should always be properl y 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.
16 SAFETY Operator Safety Ice and Snow Build-up W ARNING! Ice and snow build-up may interf ere with the steering of your machine, resulting in serious injury or dea th.
17 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.
18 SAFETY Operator Safety Driving in Hilly T errain W ARNING! Climbing a hill or crossing the face of a slope may result in loss of balance and machine rol l-over , causing seri ous i njury or deat h. Use caution and good judgement when driving in hilly te rrain.
19 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.
20 SAFETY Operator Safety Inadequate Snow Conditions Since snow provides the only lubrica tion for the power slide suspension and, on liquid cooled mo dels, coo ling for the engine, adequate snow cover is a requirement for op eration of your snowmobile.
21 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.
22 SAFETY Operator Safety Windchill/T emperature Charts The following informatio n is provided to help you d etermine when tem- peratures become da ngerous for riding.
23 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 .
24 SAFETY Safety Decals and Locations Hot Surface W arning The hot surface warning is located near the rear of the tunnel: WARNING HOT SURF ACE - DO NOT TOUCH Burn may res ult. Entire top of tunnel ma y be hot. Install only accessories s pecifi- cally approved for this model by Pol ar i s.
25 SAFETY Safety Decals and Locations Reverse Warning The reverse warning decal is located on the console beside the steering post: WARNING Reverse operation, even at low speeds, can cause lo ss of control resulting in seriou s injury or death. T o avoid loss of control, always: • Look behind before and while backin g up.
26 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 speed s.
27 FEA TURES Not all models are equipped with all features shown. 8 13 5 6 7 12 11 2 1 3 4 10 9 1. Nosepan 2. Skis 3. Front Bumper (do no t use for pulling or dragg ing the snow- mobile) 4. Hood 5. Headlight 6. Windshield 7. Handlebar 8. Operator Seat 9.
28 FEA TURES Not all models are equipped with all features shown. 1. Fuel Filler Cap 2. Ig nition Switch 3. M FD Gauge 4. Engine Stop Switch 5. Throttle Control 6. Recoil Starter Handle 7. Hood Hold Down Straps 8. Parking Brake Lock 9. Ha ndlebar Grip Wa r m e r Sw i t ch 10.
29 FEA TURES Cargo Area The maximum weight capacity for the cargo area is 15 lbs. (7 kg). Install only accessories specifically approved for this model by Polaris. Always secure cargo before operating. Do not exceed the carg o area weight limit. Adjustable Headlights Adjust the headlight beam by moving th e adjuster to the left or right.
30 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 .
31 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 ( + ) 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.
32 FEA TURES Instrumentation MFD Digital Display Programs Press the MODE button to cycle thro ugh the three MFD programs: Per- formance, Engine and History .
33 FEA TURES Instrumentation MFD Digital Display Programs T rip Settings Tr i p 1 a n d Tr i p 2 ar 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 .
34 FEA TURES Instrumentation MFD Digital Display Programs Performa nce 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.
35 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).
36 FEA TURES Instrumentation MFD Digital Display Programs Engine Prog ram Altitude (if equipped) The rider can calibrate th e altimeter for current atmospheric conditions . Altimeter accuracy will be +/-300 ft. (91 m) after adjustment. TIP: Press and hold the MODE switch for ten sec- onds to switch between standard and metric units of measurement.
37 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.
38 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 reminder that service is due.
39 FEA TURES Instrumentation MFD Battery Replacement (models with clocks) If the clock function of the MFD isn't working properly , replace the battery . Replacement batteries are available from your dealer . 1. Remove the plenum from the under- side of the hoo d.
40 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 tmen t using high stre ngth double- sided tape between the two compar t ment halves or high strength single-sided tape around the outside of the compartment.
41 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 adjustments. Settings will vary from rider to rider , depending on rider weight, vehicle speed, riding style, and trail cond itions.
42 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 th e machine are at the same adjustment.
43 THE PERFECT FIT F ront Suspension Adjustments Shock Compression Damp ing (Premium Shocks) T urn the adjuster to make adjustments to the compression damping. When adjusting, we recomm end that you turn the adjuste r only one click, then test ride. Always adjust bot h shocks equally .
44 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.
45 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.
46 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.
47 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.
48 THE PERFECT FIT Rear Suspension 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.
49 THE PERFECT FIT Rear Suspension Adjustments Limiter Strap Posi tion (Ski Pressure) Ski pressure is set at the factory to deliver the optimum balance between ride and handling . If a rider prefers more ski pressure for improved steering performance, adjustments can be made to the front limiter straps.
50 THE PERFECT FIT Rear Suspension Adjustments Rear Shock Compression Damping (Pre mium Shock) T urn the adjuster 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 one click, then test ride.
51 THE PERFECT FIT Rear Suspension Adjustments Suspension Coupling On all Polaris snowmobile rear suspensi ons, 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 .
52 THE PERFECT FIT Rear Suspension 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 ount of in depen- dent movement be tween the rear torque and the front torque arm.
53 THE PERFECT FIT Rear Suspension 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 trail riding conditions.
54 THE PERFECT FIT Handlebar Adjustments Handlebar Position 1. Loosen the four bolts on the bottom of the adjuster block. If necessary , pry the blocks apart with a screwdriver . 2. Adjust the handlebar forward or rearward to the desired position. 3. T ighten the bolts.
55 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.
56 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.
57 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.
58 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.
59 PRE-RIDE INSPECTIONS Before Starting the Engine Before starting the engine, always re fer to all safety warnings pertaining to snowmobile operation.
60 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.
61 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.
62 PRE-RIDE INSPECTIONS Before Starting the Engine n Steering System W ARNING! Ice and snow build-up may interf ere with the steering of your machine, resulting in serious injury or dea th.
63 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.
64 PRE-RIDE INSPECTIONS Start the Engine and Check Before starting the engine, always re fer to all safety warnings pertaining to snowmobile operation. Never en gage the starter when the engine is running. Never start the engine with out checking all ve hicle components to be sure of proper operatio n.
65 OPERA TION Starting the Engine NOTICE: Engaging the starter when the engine is run ning WILL result in serious engine damage, especially if the tr ansmission is in reverse. Never engage the starter when the engine is runni ng. 1. T urn the key to the ON position.
66 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 one pint of Polaris injection o il for each five gal- lons of fuel.
67 OPERA TION Engine Break-In Oil Injection System Always check and fill the oil tank when refueling. See page 71. NOTICE: Serious engine damage can occur without the proper lu brication. Check the oil tank level often during t he first tank of fuel. If the oil level doesn't go down, contact your dealer immediately .
68 OPERA TION T rack W arm-Up W ARNING! A loose track or flying debris could cause serious injury or death. S tand clear of the front of the machi ne and the moving track. Never hold the snowmobile up or stand be hind it while warmin g up the track. D o not use excessive throttle during warm-up or when the track is free-hanging.
69 OPERA TION Fu e l Gasoline is highl y flammable and explosive u nder certain conditions. • 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.
70 OPERA TION Fu e l 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 us e lower than 87 octane fuel. Do not use fuel containing more than 10% ethanol (including E85).
71 OPERA TION n Oil 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 67 for oi l recommendations.
72 OPERA TION n Engine Stop Switch Push down on the engine stop switch ( + ) to ground out the ig nition and stop the engine quickly . Pull the switch up to the ON position to allow restarting.
73 OPERA TION Throttle Lever W ARNING! An improperly functioning throttle lever may cause erratic machine behavior and loss of control, which could result in serious injury or death . If the throttle lever does not work properly , DO NOT st art the engine.
74 OPERA TION Emergency Stoppi ng The following chart lists methods for stopping the snowmobile in the event of an emergency . See page 72 for more information about the engine stop switch and throttle safety switch.
75 OPERA TION Electronic Reverse (PERC t ) Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Da mage will occur to the chaincase or trans- mission if shifting is attempted when the engine is operating above idle speed .
76 OPERA TION Electronic Reverse (PERC t ) 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.
77 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.
78 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.
79 MAINTENANCE P olaris Recommended Mainte nance 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 begin ning on page 133.
80 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 .
81 MAINTENANCE P eriodic Maintenance Interval T able Item See Page 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 Condi.
82 MAINTENANCE P eriodic Maintenance Interval T able I - Inspect (clean, adjust, tighten, lubricate, replace if necessar y) C - Clean R - Replace L - Lubricate Item See Page Frequency 150 mi.
83 MAINTENANCE Lubrication Rear Suspension Lubricate the suspension pivot shafts with Polaris Pr emium All Season Grease at the intervals outlined in the Periodic Maintenance T able beginning on page 79 and before sea sonal storage. When operating in heavy , wet snow conditions, lubr icate every 500 miles (800 km).
84 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.
85 MAINTENANCE Lubrication n Chaincase Oil Check the chaincase oil leve l at the intervals outlined in the maintenance charts beginning on page 79. The sight glass (1) is located on the lower rear of the chaincase. Maintain the oil level at or slightly below the center of the sight glass (2).
86 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 of f all metal shavings from the plug. 4. Install a new sealing washer on the drain plug.
87 MAINTENANCE Spark Plugs A new engine can cause temporary spar k plug fouling du e 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.
88 MAINTENANCE Spark Plug Condition Spark plug condition is indicative of engine operation. The spark plug firing end condition sho uld 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 .
89 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 pr ocedure for spark plug installation. 4. T orque to 18-22 ft .
90 MAINTENANCE Intake Filters The intake foam filters limit snow ingestion into the intake system. When operating in loose powder snow , check the foam filters periodically to remove any accumulation of snow . NOTICE: Operating the snowmo bile with the intake filters removed may cause carburetor icing.
91 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.
92 MAINTENANCE Cooling System Coolant High T emperat ure Indicator Light CAUTION! S team and hot liquids will cause burns to your skin. Never remove the pressure cap when the engine is warm or hot. The high temperature indicator light wi ll illuminate when engine cool- ant temperature becomes too hot for safe continued operation of the engine.
93 MAINTENANCE Cooling System Bleeding the Cooling System CAUTION! S team and hot liquids will cause burn s to your skin. Never bleed the cooling system or remove the pressure cap when the engine is warm or hot. Use of a non-standard pressure cap will not allow the recovery system to function properly .
94 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 co ol completely before inspecting. CAUTION! Hot exhaust system parts can cause burns. Allow a dequate time for the exhaust system to cool.
95 MAINTENANCE Drive Chain T ension Check drive chain tension weekly and before each long trip. T o obtain correct chain tension: 1. Rotate the driven clutch counter- clockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly .
96 MAINTENANCE Brakes Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 60. Brake pads must be replaced when the brake pad material becomes thin- ner than the backing pl ate (approximately 1/16 I ).
97 MAINTENANCE Brakes Brake Fluid W ARNING! Af ter opening a bottle of brake fluid, always discard an y unused portion. Never store or use a partial bottle.
98 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. W ARNING! Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an accident and lead to serious in jury or death.
99 MAINTENANCE Lights Do not touch a halogen bulb with ba re fingers. Oil from skin leaves a residue, causing a hot spot that w ill shorten the life of the lamp. If fin- gers do touch the bu lb, clean it with an alcohol-moistened towel. Headlight Bulb Removal 1.
100 MAINTENANCE Lights T aillight/Brakelight Replacement 1. Remove the screws securing th e taillight lens. Remove the lens. 2. Push the bulb inward and turn it counterclockwise to remove it. 3. Install a new bulb. Push the bulb inward and turn it clockwise to secure it.
101 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. W ARNING! If you become aware of higher th an normal clutch engagement or an unusual vibration or shift pattern, see your dealer immedia tely .
102 MAINTENANCE Clutch System n Drive Belt Condition Periodically check the condition an d tension of the drive belt, and always carry a spare. Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and exce ssive looseness. Replace the belt if any of these conditions exist.
103 MAINTENANCE Clutch System 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.
104 MAINTENANCE Clutch System Drive Belt Removal NOTICE: Do not attempt to remove the dri ve belt after operati ng in reverse. The snowmobile must be stop ped after forward moti on to prevent damage to components during belt removal.
105 MAINTENANCE Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. 2. T o ensure satisfactory belt life, install belts so they oper- ate in the same direction of rotation by positioning the identification numbers so that you can read them.
106 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. Matte Clear Coat Cleaning Matte finish products are prone to tr apping dirt, oils and other contami- nants.
107 MAINTENANCE T rack Maintenance T rack Inspection W ARNING! Broken track rods can cause a rotating track to come off the machine, which could cause serious in jury or death. Never opera te with a damaged track. Never rotate a damaged track under power .
108 MAINTENANCE T rack Maintenance W ARNING! Moving p arts 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 measur ement or adjustments with the engin e running.
109 MAINTENANCE T rack Maintenance T rack T ension 5. 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 108. If the track needs adjustment: 6. Loosen the rear idler shaft bolt.
110 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 of f the ground.
111 MAINTENANCE Steering System Steering Inspection and Adjustment Each week, or before a long ride, ch eck all steering system fasteners and tighten if necessary .
112 MAINTENANCE Steering System Ski Alignment W ARNING! Improper ski alignment or adjust ment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski alignment or camber adjustmen t. See your Polaris deale r .
113 MAINTENANCE Steering System n Ski Skags W ARNING! W orn skis and/or skags will ad versely affect handling. Loss of vehicle control may result, causi ng seri ous injury or death.
114 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 ( + ). Do not operate the snowmobile if slide thickness measures les s than 7/16 I (1.
115 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.
116 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.
117 MAINTENANCE Extended Storage Electrical Connections Replace worn or frayed electrical wi re and connec tors. Be sure wiring harness is properly secured awa y from sharp edges, steering linkage, moving parts, and hot exhaust pa rts. T ransporting the Snowmobile Whenever the snowmobile is transported: 1.
118 POL ARIS PRODUCTS Part N o. Description Engine L ubricant s 2870791 Fogging Oil (12 oz. Aerosol) 2877882 VES Gold Plus Synthet ic 2-Cycle Engine Oil (qt.) 2877953 VES Gold Plus Synthetic 2-Cycle Engine Oil (2 qt.) 2877883 VES Gold Plus Synthetic 2-Cycle Engine Oil (gal.
119 TROUBLESHOOTING Engine T roubleshooting Unless you have experience and traini ng in two-cycle engine repair , see your dealer if technical problems arise. Problem Probable Ca use Solution Erratic engine oper- ating RPM during acceleration o r load variations Drive clutch binding • SEE YOUR DEALER.
120 TROUBLESHOOTING Engine T roubleshooting Problem Probable Ca use Solution Noise in drive sys- tem Broken drive clutch components • SEE YOUR DEALER. Bearing failure/ chaincase, jacks haft, or front drive shaft • SEE YOUR DEALER. Drive belt surface flat spots • Inspect and replace as needed.
121 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.
122 TROUBLESHOOTING Suspension T roubleshooting Problem Solution Rear suspension bot- toms too easily • Adjust torsion spring preload to achieve proper static s ag (see page 46). • Change torsion spring to stif fer optional spring (see your dealer).
123 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.
124 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 .
125 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 .
126 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 .
127 WA RRANTY Limitations of warranties 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.
128 W ARRANTY 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).
129 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.
130 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.
131 WA RRANTY U.S.A. EP A Emission s Limited W arranty This emissions li mited warranty is in addition to the Polaris standa rd limited warranty for your vehicle. Polaris Industrie s Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applica- ble U.
132 W ARRANTY U.S.A. EP A Emission s Limited W arranty The exclusive remedy for breac h of this limited warranty shall be, at the exclusive option of Polaris, repair or replacement of any defective materials, components or prod- ucts.
133 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 snowmobile. DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 150 mi.
134 MAINTENANCE L OG DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS.
135 MAINTENANCE L OG DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS.
136 INDEX A Accessories . . . . . . . . . . . . . . . . . . . 55 Adjustabl e Headlights . . . . . . . . . . . 29 Air Pollution . . . . . . . . . . . . . . . . . . . 6 Avalanches . . . . . . . . . . . . . . . . . . . . 15 B Bearings . . . . . . . . . .
137 INDEX G Gauge Cleaning. . . . . . . . . . . . . . . . . 40 H Handlebar Adjus tments. . . . . . . . . . . 54 Handlebar Angle . . . . . . . . . . . . . . . . 54 Handlebar Po sition . . . . . . . . . . . . . . 54 Headlight Adjus tment . . . . . . . .
138 INDEX S Ski Alignment . . . . . . . . . . . . . . . . 112 Ski Pressure . . . . . . . . . . . . . . . . . . . 49 Ski Skags . . . . . . . . . . . . . . . . . . . . 113 Slide Rail and Track Cooling . . . . . 67 Snow Conditions . . . . . . . . . . . .
An important point after buying a device Polaris 600 IQ ES (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 IQ ES 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 IQ ES - thus you can check whether the hardware meets your expectations. When delving into next pages of the user manual, Polaris 600 IQ ES you will learn all the available features of the product, as well as information on its operation. The information that you get Polaris 600 IQ ES will certainly help you make a decision on the purchase.
If you already are a holder of Polaris 600 IQ ES, 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 IQ ES.
However, one of the most important roles played by the user manual is to help in solving problems with Polaris 600 IQ ES. Almost always you will find there Troubleshooting, which are the most frequently occurring failures and malfunctions of the device Polaris 600 IQ ES 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
