Polaris 600 LX User Manual

7INTRODUCTIONVehicle Identification NumbersRecord your snowmobile's identification numbers and key number in the spaces provided. Remove the spar

97MAINTENANCEBrakesBrake FluidWARNING! After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle.

98MAINTENANCEBrakesBleeding the Hydraulic Brake SystemAir in the hydraulic brake system will cause spongy brake lever action. Bleed the system before

99MAINTENANCELightsDo 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

100MAINTENANCELightsTaillight/Brakelight Replacement1. Remove the screws securing the taillight lens. Remove the lens.2. Push the bulb inward and turn

101MAINTENANCEClutch SystemPeriodically inspect clutch sheaves for damage, wear or belt residue. To maintain optimum performance, clean with non-oil b

102MAINTENANCEClutch Systemn Drive Belt ConditionPeriodically check the condition and tension of the drive belt, and always carry a spare. Inspect the

103MAINTENANCEClutch Systemn Drive Belt DeflectionMeasure belt deflection with both clutches at rest and in their full neutral position.Place a straig

104MAINTENANCEClutch SystemDrive Belt Removal NOTICE: Do not attempt to remove the drive belt after operating in reverse. The snowmobile must be stopp

105MAINTENANCEClutch SystemDrive Belt Installation1. Drop the drive belt over the drive clutch and pull back the slack.2. To ensure satisfactory belt

106MAINTENANCEFall Tune-UpFor maximum performance, arrange for a fall service tune-up with your Polaris dealer. His experienced and trained service te

8SAFETYOperator SafetyThe following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these wor

107MAINTENANCETrack MaintenanceTrack InspectionWARNING! Broken track rods can cause a rotating track to come off the machine, which could cause seriou

108MAINTENANCETrack MaintenanceWARNING! Moving parts can cut and crush body parts. When performing the checks and adjustments recommended on the follo

109MAINTENANCETrack MaintenanceTrack Tension5. Check for specified slack between the wear surface of the track clip and the plastic slider. Refer to t

110MAINTENANCETrack Maintenancen Track AlignmentPeriodically check that the track is centered and running evenly on the slide rails. Misalignment will

111MAINTENANCESteering SystemSteering Inspection and AdjustmentEach week, or before a long ride, check all steering system fasteners and tighten if ne

112MAINTENANCESteering SystemSki AlignmentWARNING! Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injur

113MAINTENANCESteering Systemn Ski SkagsWARNING! Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causing se

114MAINTENANCESteering Systemn Rail Slide WearMeasure slide thickness at several points along the rail. Have your dealer replace the slide when it&apo

115MAINTENANCEExtended StorageOff-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolo

116MAINTENANCEExtended StorageBearingsGrease the jackshaft and drive shaft clutch side bearings with Polaris Premium All-Season Grease or a similar hi

9SAFETYOperator SafetyFollow the recommended maintenance program beginning on page 79 of this manual to ensure that all critical components on the sno

117MAINTENANCEExtended StorageElectrical ConnectionsReplace worn or frayed electrical wire and connectors. Be sure wiring harness is properly secured

118POLARIS PRODUCTSPart No. DescriptionEngine Lubricants2870791 Fogging Oil (12 oz. Aerosol)2877882 VES Gold Plus Synthetic 2-Cycle Engine Oil (qt.)28

119TROUBLESHOOTINGEngine TroubleshootingUnless you have experience and training in two-cycle engine repair, see your dealer if technical problems aris

120TROUBLESHOOTINGEngine TroubleshootingProblem Probable Cause SolutionNoise in drive sys-temBroken drive clutch components• SEE YOUR DEALER.Bearing f

121TROUBLESHOOTINGEngine TroubleshootingProblem Probable Cause SolutionEngine turns but fails to startFaulty ignition • Install new spark plug(s). If

122TROUBLESHOOTINGSuspension TroubleshootingProblem SolutionRear suspension bot-toms too easily • Adjust torsion spring preload to achieve proper stat

123TROUBLESHOOTINGDrive Belt TroubleshootingBelt Wear/Burn DiagnosisCauses SolutionsDriving at low RPM • Drive at higher RPMs. Gear the machine down.

124WARRANTYService and Warranty InformationObtaining Service and Warranty AssistanceRead and understand the service data and the Polaris warranty info

125WARRANTYService and Warranty InformationPolaris Anti-Theft SystemThe Polaris anti-theft system (PATS) monitoring program is designed to aid owners

126WARRANTYLimited WarrantyPolaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM-ITED WARRANTY on all components of the Polar

10SAFETYOperator SafetyStay Clear of TrackYour snowmobile is propelled by a revolving track that must be partially exposed for proper operation.WARNIN

127WARRANTYLimitations of warranties and remediesALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FI

128WARRANTYConditions and ExclusionsIn order to qualify for warranty, the product must have been properly set up and tested by a Polaris Dealer (if ap

129WARRANTYPolaris Second Year Engine Service ContractSecond Year Engine Service Contract is standard on all eligible new and unused snow-mobiles that

130WARRANTYExported VehiclesEXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOL

131WARRANTYU.S.A. EPA Emissions Limited WarrantyThis emissions limited warranty is in addition to the Polaris standard limited warranty for your vehic

132WARRANTYU.S.A. EPA Emissions Limited WarrantyThe exclusive remedy for breach of this limited warranty shall be, at the exclusive option of Polaris,

133MAINTENANCE LOGPresent this section of your manual to your dealer each time your snow-mobile is serviced. This will provide you and future owners w

134MAINTENANCE LOGDATE MILES(KM)TECHNICIAN SERVICE PERFORMED / COMMENTS

135MAINTENANCE LOGDATE MILES(KM)TECHNICIAN SERVICE PERFORMED / COMMENTS

136INDEXAAccessories . . . . . . . . . . . . . . . . . . . 55Adjustable Headlights . . . . . . . . . . . 29Air Pollution . . . . . . . . . . . .

11SAFETYOperator SafetyRiding ApparelBe prepared, be warm and be com-fortable when riding. Be aware of the weather forecast, especially the windchill,

137INDEXGGauge Cleaning. . . . . . . . . . . . . . . . . 40HHandlebar Adjustments. . . . . . . . . . . 54Handlebar Angle. . . . . . . . . . . . . .

138INDEXSSki Alignment . . . . . . . . . . . . . . . . 112Ski Pressure . . . . . . . . . . . . . . . . . . . 49Ski Skags . . . . . . . . . . . . .

12SAFETYOperator SafetyDisabled OperatorsSafe operation of this rider-active vehicle requires good judgement and physical skills. Operators with cogni

13SAFETYOperator SafetyRider CapacityDriving 1-Up - Some Polaris snowmobiles are designed for a single rider only. A decal on the console of these mod

14SAFETYOperator SafetyDriver AwarenessSlow down when traveling near poles, posts, or other obstacles. Be especially alert if you're snowmobiling

15SAFETYOperator SafetyAvalanchesSnowmobilers should always be properly trained and equipped before traveling in mountainous terrain:• Take an avalanc

16SAFETYOperator SafetyIce and Snow Build-upWARNING! Ice and snow build-up may interfere with the steering of your machine, resulting in serious injur

17SAFETYOperator SafetyDriving DownhillWhen riding downhill, shift your weight to the rear of the machine and reduce your speed to a minimum. Apply ju

18SAFETYOperator SafetyDriving in Hilly TerrainWARNING! Climbing a hill or crossing the face of a slope may result in loss of balance and machine roll

19SAFETYOperator SafetyDrive BeltDo not operate the engine with the drive belt removed.Any servicing that requires operation without a belt must be pe

20SAFETYOperator SafetyInadequate Snow ConditionsSince snow provides the only lubrication for the power slide suspension and, on liquid cooled models,

21SAFETYOperator SafetyDriving ResponsiblyEvery snowmobile handles differently, and even the most docile condi-tions may become dangerous if operators

22SAFETYOperator SafetyWindchill/Temperature ChartsThe following information is provided to help you determine when tem-peratures become dangerous for

23SAFETYSafety Decals and LocationsWarning decals have been placed on the snowmobile for your protec-tion. Read and follow the instructions of the dec

24SAFETYSafety Decals and LocationsHot Surface WarningThe hot surface warning is located near the rear of the tunnel:WARNINGHOT SURFACE - DO NOT TOUCH

25SAFETYSafety Decals and LocationsReverse WarningThe reverse warning decal is located on the console beside the steering post:WARNINGReverse operatio

26SAFETYSafety Decals and LocationsOperation Warning• To avoid serious injury or death, read and understand all warnings and the Owner's Manual b

WARNINGRead, understand, and follow all of the instructions and safety precautions in this manual and on all product labels.Failure to follow the safe

27FEATURESNot all models are equipped with all features shown.813567121121341091. Nosepan2. Skis3. Front Bumper (do not use for pulling or dragging th

28FEATURESNot all models are equipped with all features shown.1. Fuel Filler Cap2. Ignition Switch3. MFD Gauge4. Engine Stop Switch5. Throttle Control

29FEATURESCargo AreaThe maximum weight capacity for the cargo area is 15 lbs. (7 kg). Install only accessories specifically approved for this model by

30FEATURESInstrumentationMFD Component IdentificationDigital Display IdentificationItem1 Analog (if equipped)2 Digital Gauge3 CHECK ENGINEIndicator (c

31FEATURESInstrumentationMFD SettingsWith the engine running, use the MFD Control Switch to set the MFD display to your preference. The rocker switch

32FEATURESInstrumentationMFD Digital Display ProgramsPress the MODE button to cycle through the three MFD programs: Per-formance, Engine and History.

33FEATURESInstrumentationMFD Digital Display ProgramsTrip SettingsTrip 1 and Trip 2 are odometers used to check fuel mileage or to keep track of dista

34FEATURESInstrumentationMFD Digital Display ProgramsPerformance ProgramClock Setting1. While in the CLOCK display, press and hold the SET button for

35FEATURESInstrumentationMFD Digital Display ProgramsEngine ProgramThe Engine Program automatically displays the engine coolant tempera-ture, engine h

36FEATURESInstrumentationMFD Digital Display ProgramsEngine ProgramAltitude (if equipped)The rider can calibrate the altimeter for current atmospheric

1WELCOMEThank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris enthusiasts. Be sure to visit us online at www.pol

37FEATURESInstrumentationMFD Digital Display ProgramsHistory ProgramThe History Program automatically displays electrical system voltage level and fue

38FEATURESInstrumentationMFD Digital Display ProgramsService Interval ReminderThe gauge logs the number of engine hours between service reminders. Whe

39FEATURESInstrumentationMFD Battery Replacement (models with clocks)If the clock function of the MFD isn't working properly, replace the battery

40FEATURESInstrumentationMFD Battery Replacement (models with clocks)6. Install a new battery with fingers only.7. Seal the end of the battery compart

41THE PERFECT FITFront Suspension AdjustmentsIndependent Front Suspension (IFS)Break in the suspension for about 150 miles (240 km) before making any

42THE PERFECT FITFront Suspension AdjustmentsShock Spring PreloadIncreasing spring preload will increase ski-to-ground pressure. Decreasing spring pre

43THE PERFECT FITFront Suspension AdjustmentsShock Compression Damping (Premium Shocks)Turn the adjuster to make adjustments to the compression dampin

44THE PERFECT FITRear Suspension AdjustmentsRider weight, riding style, trail conditions, and vehicle speed all affect suspension action.Each rear sus

45THE PERFECT FITRear Suspension AdjustmentsSuspension Performance Tips• Rider weight usually determines the position at which the spring pre-load sho

46THE PERFECT FITRear Suspension AdjustmentsInitial Spring Preload Setting (Sag Method)To set up the rear suspension tor-sion spring preload, measure

2POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-tries Inc.Copyright 2009 Polaris Sales Inc. All information contained with

47THE PERFECT FITRear Suspension AdjustmentsInitial Spring Preload Setting (Sag Method)To determine sag, commonly referred to as ride-in, subtract mea

48THE PERFECT FITRear Suspension AdjustmentsTorsion Spring PreloadTo adjust rear torsion spring preload, rotate the three-position cam using the engin

49THE PERFECT FITRear Suspension AdjustmentsLimiter Strap Position (Ski Pressure)Ski pressure is set at the factory to deliver the optimum balance bet

50THE PERFECT FITRear Suspension AdjustmentsRear Shock Compression Damping (Premium Shock)Turn the adjuster on the shock reservoir to make adjustments

51THE PERFECT FITRear Suspension AdjustmentsSuspension CouplingOn all Polaris snowmobile rear suspensions, there are two torque arms that control the

52THE PERFECT FITRear Suspension AdjustmentsRear To Front Coupling and the Rear Rear Scissor Stop (RRSS)The rear rear scissor stop (RRSS) couples the

53THE PERFECT FITRear Suspension AdjustmentsWeight Transfer During AccelerationThe preferred method for control-ling weight transfer during accel-erat

54THE PERFECT FITHandlebar AdjustmentsHandlebar Position1. Loosen the four bolts on the bottom of the adjuster block. If necessary, pry the blocks apa

55THE PERFECT FITAccessoriesPolaris offers a wide range of accessories for your snowmobile to help make each ride more enjoyable.Use only Polaris part

56THE PERFECT FITTraction ProductsStudsBefore equipping your machine with traction products, be aware of the laws in your area pertaining to the use o

3TABLE OF CONTENTSIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5This section contains helpful information for owners and dri

57THE PERFECT FITTraction ProductsnCarbide SkagsA skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile a

58PRE-RIDE INSPECTIONSPre-Ride ChecklistInspect all items on the checklist for proper operation or condition before each use of the snowmobile. Proced

59PRE-RIDE INSPECTIONSBefore Starting the EngineBefore starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Ne

60PRE-RIDE INSPECTIONSBefore Starting the Enginen BrakesAlways check the following items for proper operation before starting the engine.Brake Lever T

61PRE-RIDE INSPECTIONSBefore Starting the Enginen Parking Brake Lever LockUse the parking brake lever lock only when you want the machine to remain st

62PRE-RIDE INSPECTIONSBefore Starting the Enginen Steering SystemWARNING! Ice and snow build-up may interfere with the steering of your machine, resul

63PRE-RIDE INSPECTIONSBefore Starting the Enginen Hood LatchesThe hood of the snowmobile protects the operator from moving parts as well as aiding in

64PRE-RIDE INSPECTIONSStart the Engine and CheckBefore starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Ne

65OPERATIONStarting the EngineNOTICE: Engaging the starter when the engine is running WILL result in serious engine damage, especially if the transmis

66OPERATIONEngine Break-InNo single action on your part is as important to long, trouble-free machine life as proper break-in of a new or rebuilt engi

4

67OPERATIONEngine Break-InOil Injection SystemAlways check and fill the oil tank when refueling. See page 71.NOTICE: Serious engine damage can occur w

68OPERATIONTrack Warm-UpWARNING! A loose track or flying debris could cause serious injury or death. Stand clear of the front of the machine and the m

69OPERATIONFuelGasoline is highly flammable and explosive under certain conditions.• Always exercise extreme caution whenever handling gasoline.• Alwa

70OPERATIONFuelPolaris recommends the use of 91 octane or higher fuel. Although 87 octane fuel is usable, some engine performance will be lost and fue

71OPERATIONn OilLow Oil Indicator LightThe low oil indicator light will alert the operator if the oil level is low. Visually check for oil in the bott

72OPERATIONn Engine Stop SwitchPush down on the engine stop switch (+) to ground out the ignition and stop the engine quickly. Pull the switch up to t

73OPERATIONThrottle LeverWARNING! An improperly functioning throttle lever may cause erratic machine behavior and loss of control, which could result

74OPERATIONEmergency StoppingThe following chart lists methods for stopping the snowmobile in the event of an emergency. See page 72 for more informat

75OPERATIONElectronic Reverse (PERCt)Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death.

76OPERATIONElectronic Reverse (PERCt)Engaging Reverse1. Stop the snowmobile and leave the engine idling.2. Make sure the area behind your vehicle is c

5INTRODUCTIONImportant Notes for Owners and DriversAfter reading this manual, store it in the snowmobile for convenient ref-erence. It should remain w

77OPERATIONDaily StorageAt the end of each ride, park the snowmo-bile on a level surface and support it at the rear with an appropriate track stand. T

78MAINTENANCEEmission Control InformationAny qualified repair shop or qualified person may maintain, replace, or repair the emission control devices o

79MAINTENANCEPolaris Recommended Maintenance ProgramTo ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenanc

80MAINTENANCEPeriodic Maintenance Interval TableThe following chart is a guide based on average riding conditions. You may need to increase frequency

81MAINTENANCEPeriodic Maintenance Interval TableItem See PageFrequency150 mi.(240 km)500 mi.(800 km)1000 mi.(1600 km)2000 mi.(3200 km)Pre-SeasonBRAKES

82MAINTENANCEPeriodic Maintenance Interval TableI - Inspect (clean, adjust, tighten, lubricate, replace if necessary)C - Clean R - Replace L - Lubrica

83MAINTENANCELubricationRear SuspensionLubricate the suspension pivot shafts with Polaris Premium All Season Grease at the intervals outlined in the P

84MAINTENANCELubricationDriveshaft BearingInject grease into the fitting on the speedometer sensor housing until grease purges from the seal on the in

85MAINTENANCELubricationn Chaincase OilCheck the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 79. The sig

86MAINTENANCELubricationChaincase OilOil Change 1. Position the vehicle on a level surface.2. Remove the drain plug (4) and drain the oil into a drain

6INTRODUCTIONPreservation of the EnvironmentPolaris is committed to supporting an environmental education cam-paign. We encourage state and provincial

87MAINTENANCESpark PlugsA new engine can cause temporary spark plug fouling due to the preser-vative added during the assembly process. Avoid prolonge

88MAINTENANCESpark Plug ConditionSpark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the

89MAINTENANCESpark Plug Removal and Replacement1. Remove the spark plug cap.2. Using the special wrench provided in the tool pouch, rotate the spark p

90MAINTENANCEIntake FiltersThe intake foam filters limit snow ingestion into the intake system. When operating in loose powder snow, check the foam fi

91MAINTENANCECooling SystemCoolantThe coolant supplied in the system at the factory is a 50/50 mixture of ethylene-glycol and distilled water, which w

92MAINTENANCECooling SystemCoolant High Temperature Indicator LightCAUTION! Steam and hot liquids will cause burns to your skin. Never remove the pres

93MAINTENANCECooling SystemBleeding the Cooling System CAUTION! Steam and hot liquids will cause burns to your skin. Never bleed the cooling system or

94MAINTENANCEExhaust SystemCheck the exhaust system for wear or damage at approximately 2000 miles (3200 km). Always allow the engine and exhaust syst

95MAINTENANCEDrive Chain TensionCheck drive chain tension weekly and before each long trip. To obtain correct chain tension: 1. Rotate the driven clut

96MAINTENANCEBrakesHydraulic Brake InspectionInspect the brake lever reserve before each use of the snowmobile. See page 60.Brake pads must be replace