Polaris 600RR User Manual

7SAFETYOperator SafetyThe following signal words and symbols appear throughout thismanual and on your vehicle. Your safety is involved when these word

97MAINTENANCEExtended StorageElectrical Con n ectio n sSeparate electrical connector blocks and clean corrosive build-up fromconnectors. Lubricate or

98MAINTENANCETransporting the SnowmobileWhenever the snowmobile is transported:1. Turn the fuel valveclockwise to OFF to shutoff the fuel supply (1).T

99POLARIS PRODUCTSPart No. DescriptionEngine Lubricants2870791 Fogging Oil (12 oz. Aerosol)2873023 Synthetic 2-Cycle Racing Oil (gal.)2871098 Premium

100TROUBLESHOOTINGEngine TroubleshootingCAUTION: Unless you have experience and training in two-cycleengine repair, see your dealer if technical probl

101TROUBLESHOOTINGEngine TroubleshootingProblem Probable Cause SolutionNoise in drivesystemBroken drive clutchcomponentsBearing failure/chaincase, jac

102TROUBLESHOOTINGEngine TroubleshootingProblem Probable Cause SolutionEngine turnsbut fails to startFaulty ignitionNo fuel to engineFlooded engine (n

103TROUBLESHOOTINGSuspension TroubleshootingProblem Solution (perform only one change at a time)Rear suspensionbottoms too easily-Increase torsion spr

104TROUBLESHOOTINGBelt TroubleshootingBelt Wear/BurnBelt Wear/Burn DiagnosisCauses SolutionsDriving at low RPM Drive at higher RPMs. Gear the machine

105WARRANTYService And Warranty InformationObtaining Service and Warranty AssistanceRead and understand the service data and the P olaris warrantyinfo

106WARRANTYLimited WarrantyPolaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM-ITED WARRANTY on all components of the Polar

8SAFETYOperator SafetyFollow the recommended m aintenance program outlined beginning onpage 60 of this manual to ensure that all critical components o

107WARRANTYLimitations of warranties and remediesALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IM-PLIED WARRANTIES OF MERCHANTABILITY AND F

108WARRANTYConditions and ExclusionsIn order to qualify for warranty, the product must have been properly set up and tested bya Polaris Dealer (if app

109WARRANTYPolaris Second Year Engine Service ContractSecond Year Engine Service Contract is standard on all eligible new and unusedsnowmobiles that w

110WARRANTYExported Veh iclesEXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SO

111WARRANTYSnowmobile Engine Emissions Limited WarrantyThis snowmobile engine emissions limited warranty is in addition to the Polaris standardlimited

112MAINTENANCE RECORDDATE MILES/KM TECHNICIAN SERVICE PERFORMED / COMMENTS150 mi.(240 km)500 mi.(800 km)1000 mi.(1600 km)2000 mi.(3200 km)

113MAINTENANCE RECORDDATE MILES/KM TECHNICIAN SERVICE PERFORMED / COMMENTS

114MAINTENANCE RECORDDATE MILES/KM TECHNICIAN SERVICE PERFORMED / COMMENTS

115INDEXAAccessories 40-43...Altitude Ignition Setting 29...Avalanches 13...BBefore Starting the Engine 45-48..

116INDEXJJetting Guidelines 56...LLighting Check 49...Lubrication 64-66...MMaintenance Interval Table 61-63..

9SAFETYOperator SafetyRiding ApparelBe prepared, be warm and becomfortable when riding. Beaware of the weatherforecast, especially thewindchill, and d

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

11SAFETYOperator SafetyDriver AwarenessSlow down when traveling near poles,posts, or other obstacles. Be especiallyalert if you’re snowmobiling after

12SAFETYOperator SafetyDisabled OperatorsSafe operation of this rider-active vehicle requires good judgement andphysical skills. Operators with cognit

13SAFETYOperator SafetyAvalanch esSnowmobilers should always be properlytrained and equipped before traveling inmountainous terrain:S Take an avalanch

14SAFETYOperator SafetyExcessive SpeedWARNINGHigh speed driving, especially at night, could result in serious injury ordeath. Always reduce speed when

15SAFETYOperator SafetyDriving in Hilly TerrainWARNINGClimbing a hill or crossing the face of a slope may result in loss ofbalance and machine roll-ov

16SAFETYOperator SafetyDrive BeltDo not operate the engine with the drive belt removed.Any servicing that requires operation without a belt must be pe

17SAFETYOperator SafetyInadequate Snow ConditionsWARNINGDo not drive for prolonged periods on blacktop, gravel, or ice. Doing socould cause irreversib

18SAFETYOperator SafetyDriving ResponsiblyEvery snowmobile handles differently, and even the most docileconditions may become dangerous if operators d

19SAFETYOperator SafetyWindchill/Temperature Ch artsThe following information i s provided to help you determine whentemperatures become dangerous for

20SAFETYSafety Decals and LocationsWarning decals have been placed on the snowmobile for yourprotection. Read and follow the instructions of the decal

21SAFETYSafety Decals and LocationsTrack WarningThe track warning decal is located on the rear of the tunnel:Passenger WarningThis snowmobile is desig

22SAFETYSafety Decals and LocationsOperation Warning+

23SAFETYSafety Decals and LocationsOperation Warning

24FEATURES AND CONTROLS1. Brake Lever2. Oil Light (600RR only)3. Tachometer4. Temperature Light5. Engine St op Switch6. Throttle Control7. Choke Contr

25FEATURES AND CONTROLS1. Handlebar2. Windshield3. Headlight4. Hood5. Nosepan6. Skis7. Track8. Suspension9. Snow Flap10. Taillights11. Seat94111078561

26FEATURES AND CONTROLSPolaris DRAGON Ignition System (600 IQ Racer)Your snowmobile is equipped with an ignition system feature thatimproves competiti

WARNINGRead, understand, and follow all of theinstructions and safety precautions inthis manual and on all product labels.Failure to follow the safety

27FEATURES AND CONTROLSPolaris DRAGON Ignition System (600 IQ Racer)DRAGON Mode Operation1. Warm up the engine andtrack. See page 54.2. When staged at

28FEATURES AND CONTROLSElectronic Reverse (PERCt) (600RR)Electronic reverse will activate only if the engine RPM is below 4000.If your machine is runn

29FEATURES AND CONTROLSElectronic Reverse (PERCt) (600RR)Disengaging Reverse1. St op the snowmobile and leave the engine idling.2. Push the reverse bu

132430THE PERFECT FITIQ Front Suspension AdjustmentsIndependent Front Suspension (IFS)Break in the suspension for about 150 miles (240 km) before maki

31THE PERFECT FITIQ Front Suspension AdjustmentsWARNINGAlways verify ski alignment before making adjustments to the IFS. Seepage 92 to check alignment

132THE PERFECT FITIQ Front Suspension AdjustmentsFront Shock Spring PreloadIncreasing spring preload will increaseski-to-ground pressure. Decreasing s

33THE PERFECT FITIQ Front Suspension AdjustmentsShock ValvingWalker/Evans shocks can be revalved if spring preload alone isn’tsufficient and further a

34THE PERFECT FITRear Suspension AdjustmentsRider weight, riding style, t rail conditions, and vehicle speed all affectsuspension action.Each rear sus

35THE PERFECT FITIQ Rear Suspension AdjustmentsRear Torsion Spring TensionTo adjust rear torsion spring tension, rotate the three-position camusing th

36THE PERFECT FITIQ Rear Suspension AdjustmentsSuspension CouplingOn all Polaris snowmobile rear suspensions, there are two torque armsthat control th

1WELCOMEThank you for purchasing a P olaris vehicle, and welcome to ourworld-wide family of Polaris owners. We proudly produce an excitingline of util

37THE PERFECT FITIQ Rear Suspension AdjustmentsRear Rear Scissor Stop (RRSS)The rear rear scissor stop (RRSS) couples the movement of the reartorque a

38THE PERFECT FITIQ Rear Suspension AdjustmentsWeight Transfer During AccelerationIQ Rear Rear Scissor Stop (RRSS)The preferred method for controlling

39THE PERFECT FITHandlebar AdjustmentsHandlebar with Riser Block1. Remove the handlebarcover to expose thehandlebar mounting hardware.2. Using a 1/4”

40THE PERFECT FITAccessoriesPolaris offers a wide range of accessories for your snowmobile to helpmake each ride more enjoyable. See your dealer for a

41THE PERFECT FITAccessoriesTraction ProductsAnother way to tailor your machine is to install traction products. Seeyour dealer about installing studs

42THE PERFECT FITAccessoriesCAUTIONAggressive studding patterns may require grinding protruding stud boltsflush to prevent idler wheel damage. Maintai

43THE PERFECT FITAccessoriesWear StripsPolaris IQ models are manufactured with tunnel wear strips or wearstrip coolers installed. To avoid excessive t

44PRE-RIDE INSPECTIONSPre -Ride ChecklistInspect all items on the checklist for proper operation or conditionbefore each use of the snowmobile. Proced

45PRE-RIDE INSPECTIONSBefore Starting the EngineWARNINGWorn, damaged, or malfunctioning components may cause s erious injuryor death. Before starting

46PRE-RIDE INSPECTIONSBefore Starting the EnginenHydraulic BrakesAlways check thefollowing items to assureproper operation beforestarting t he engine.

2POLARIS and POLARIS THE WAY OUT are registered trademarks of PolarisIndustries Inc.Copyright 2007 Polaris Sales Inc. All information contained within

47PRE-RIDE INSPECTIONSBefore Starting the EnginenParking Brake Lever LockYour snowmobile may have a parking brake lever lock located over t hebrake le

48PRE-RIDE INSPECTIONSBefore Starting the EnginenCheck for Proper Operation of Steering SystemManually turn the s kis completely t o the right and t o

49PRE-RIDE INSPECTIONSStart the Engine and CheckBefore starting the engine, always refer to all safety warningspertaining to snowmobile operation. Nev

50OPERATIONEngine Break-InNo single action on your part is as important to long, trouble-freemachine life as proper break-in of a new or rebuilt engin

51OPERATIONEngine Break-InFuel RecommendationsCAUTIONUsing fuels with a lower than recommended octane or operating withobstructed fuel systems will re

52OPERATIONEngine Break-InFuel RecommendationsWARNINGGasoline is highly flammable and explosive under certain conditions.S Always exercise extreme cau

53OPERATIONStarting the EngineStarting a Cold EngineDo not depress the throttle until the engine starts.1. Attach the tether cord to the tether switch

54OPERATIONEngine and Track Warm-UpWARNINGA loose track or flying debris could cause serious personal injury ordeath. Stand clear of the front of the

55OPERATIONSlide Rail and Track CoolingCAUTIONInadequate c ooling and lubrication will lead to overheating of the slide railand track, resulting in pr

56OPERATIONCarburetionProper carburetor adjustment is critical. A lean mixture (too much air,too little fuel) m ay result in piston burning, bearing f

3TABLE OF CONTENTSIntroduction 4...This section contains helpful information for owners and drivers andillustrates the loc

57OPERATIONn Engine Stop SwitchPush down on the engine stopswitch (1) to stop the engine in anemergency. To restart the engine,pull the switch up to t

58OPERATIONDaily StorageAt the end of each ride, park thesnowmobile on a level surface andsupport it at the rear with an appropriatetrack stand. The t

59MAINTENANCEEmission Control InformationAny qualified repair shop or qualified person may maintain, replace, orrepair the emission control devices or

60MAINTENANCEPolaris Recommended Maintenance ProgramTo ensure many trouble-free miles of snowmobiling enjoyment, followrecommended regular maintenance

61MAINTENANCEPeriodic Maintenance Interval TableThe following chart is a guide based on average riding conditions. Youmay need to increase frequency b

62MAINTENANCEPeriodic Maintenance Interval TableSeePFrequencyItemPage150 mi.(240 km)500 mi.(800 km)1000 mi.(1600 km)2000 mi.(3200 km)Pre-SeasonBrakesH

63MAINTENANCEPeriodic Maintenance Interval TableSeePFrequencyItemPage150 mi.(240 km)500 mi.(800 km)1000 mi.(1600 km)2000 mi.(3200 km)Pre-SeasonChassis

64MAINTENANCELubricationLack of lubrication will adversely affect your ride and the life ofcomponents. Lubricate with Polaris Premium All Season Greas

65MAINTENANCELubricationFront SuspensionTwo components of the IQ front suspension and steering requirelubrication.S Grease the left and right spindles

66MAINTENANCELubricationnChaincase Oil LevelCheck the chaincase oil level at the intervals outlined in themaintenance charts beginning on page 60.To c

4INTRODUCTIONImportant Notes for Owners and DriversAfter reading this manual, store it in t he snowmobile for convenientreference. It should remain wi

67MAINTENANCESpark PlugsA spark plug with a heat range too high will cause engine damage. Aspark plug with a heat range too l ow will cause excessive

68MAINTENANCESpark PlugsSpark plug condition is i ndicative of engine operation. The spark plugfiring end condition should be read after the engine ha

69MAINTENANCEIntake FilterThe i ntake foam filterslimit snow ingestion intothe intake system. Whenoperating in loose powdersnow, check the top of thef

70MAINTENANCEVariable Exhaust System (VES)Maintena nc e of the VES is limited to a periodic inspection andclea ning of system components. Every 1000 t

71MAINTENANCECarburetorThe number stamped in the end of the main jet indicates the jet size.The jet installed at the time of manufacture is not necess

72MAINTENANCEExhaust SystemCheck the exhaust system for wear or damage at approximately 1000miles (1600 km). To inspect, allow t he engine and exhaust

73MAINTENANCEEngine CoolingCoolant MixtureThe coolant supplied in the system is a 50/50 mixture ofethylene-glycol and distilled water. This mixture pr

74MAINTENANCEEngine CoolingFlushing the Cooling SystemTo ensure that the coolant maintains its ability to protect the engine,the system should be comp

75MAINTENANCEEngine CoolingBleeding t h e Cooling System3. Tip the snowmobile slightly onto its right side. Cycle the RPMfrom idle to enough RPM (4000

76MAINTENANCEDrive Chain TensionTo obtain correct chain tension:1. Rotate the driven clutchcounterclockwise to move allchain slack to the tensionersid

5INTRODUCTIONPreservation of the EnvironmentPolaris is committed to supporting an environmental educationcampaign. We encourage governments to adopt r

77MAINTENANCEn Hydraulic Brake InspectionFrequently inspect thebrake lever reserve.Squeeze the brake lever.It should move no closerto the handgrip tha

78MAINTENANCEBrakesBrake Components1. Brake Caliper2. Chaincase3. Brake Disc4. Backing P late5. Brake Pad Material (Replace when thickness is less tha

79MAINTENANCEBrakesBrake FluidWARNINGAfter opening a bottle of brake fluid, always discard any unused portion.Never store or use a partial bottle. Bra

80MAINTENANCEBrakesBleeding the Hydraulic Brake SystemAir in the hydraulic brake system will cause spongy brake lever action.Bleed the system before o

81MAINTENANCEHeadlightsHeadlight AdjustmentThe headlight may be adjusted for vertical aim using the followingprocedure:1. Place the snowmobile on a le

82MAINTENANCEHeadlightsNOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leavesa residue, causing a hot spot that will shorten the li

83MAINTENANCEClutch SystemPeriodically inspect the clutch sheaves for damage, wear, or beltresidue. To maintain optimum performance, clean with non-oi

84MAINTENANCEClutch SystemnDrive Belt ConditionPeriodically check the condition and tension of the drive belt, andalways carry a spare belt. For impro

85MAINTENANCEClutch SystemnDrive Belt DeflectionMeasure belt deflection with bothclutches at rest and in their fullneutral position.Place a straight e

86MAINTENANCETorque StopIf your snowmobile is equippedwith an engine torque stop (1),periodically check torque stopclearance. With clutches inproper a

6INTRODUCTIONVehicle Identification NumbersRecord your snowmobile’s identification numbers in the spacesprovided.Vehicle Model Number:Tunnel VIN:(lowe

87MAINTENANCEChain TensionMaintain the proper chain tension as outlined on page 76.Fall Tune-UpFor maximum performance, arrange for a fall service tun

88MAINTENANCETrack MaintenanceWARNINGMoving parts can cut and crush body parts. When performing the checksand adjustments recommended on the following

89MAINTENANCETrack MaintenanceIf the track needs adjustment (continued):8. Repeat measurement on the other side of the track.NOTE: Check more frequent

90MAINTENANCETrack MaintenanceTrack In spectionWARNINGBroken track rods are a serious safety hazard. They can cause a rotatingtrack to come off the ma

91MAINTENANCESteering SystemSteering In sp ection an d AdjustmentEach week, or before a long ride, check all fasteners and tighten ifnecessary. Specif

92MAINTENANCESteering SystemSki AlignmentWARNINGImproper ski alignment or adjustment may cause loss of steering control,resulting in serious injury or

A93MAINTENANCESteering SystemnSki SkagsWARNINGWorn skis and/or skags will adversely affect handling. Loss of vehiclecontrol may result, causing seriou

A7/16″(1.1 cm)94MAINTENANCESuspension MaintenancenRail Slide WearMeasure slide thickness atseveral points along therail. Have your dealerreplace the s

95MAINTENANCEExtended StorageOff-season or extended storage of your snowmobile requires preventivemeasures to aid against deterioration and to prolong

96MAINTENANCEExtended StorageEngine and Carburetor ProtectionProper preparation of the engine and fuel system is vital to theprevention of rust and co