2007 Polaris 600 HO IQ Owners Manual
2007 Polaris 600 HO IQ Manual
2007 Polaris 600 HO IQ manual content summary:
- 2007 Polaris 600 HO IQ | Owners Manual - Page 1
- 2007 Polaris 600 HO IQ | Owners Manual - Page 2
For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 Phone (763) 417-8650 Fax (763) 542-0599 Part No. 9920459 Rev 02 Printed in USA - 2007 Polaris 600 HO IQ | Owners Manual - Page 3
WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. WARNING The engine exhaust from this product - 2007 Polaris 600 HO IQ | Owners Manual - Page 4
operation of your vehicle, be sure to follow the instructions and recommendations in this owner's manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master - 2007 Polaris 600 HO IQ | Owners Manual - Page 5
the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A. 2007 600 HO IQ/600 HO SwitchBack Owner's Manual P/N 9920459 2 - 2007 Polaris 600 HO IQ | Owners Manual - Page 6
of important identification numbers that should be recorded in the owner's manual. TABLE OF CONTENTS Safety ...6 This section describes safe vehicle in your snowmobile's regular maintenance. Polaris Products...Troubleshooting ...Warranty ...Maintenance Log ...Index ... 122 123 129 138 140 3 - 2007 Polaris 600 HO IQ | Owners Manual - Page 7
of the tunnel): _____ Engine Serial Number (on recoil housing): _____ Key Number: _____ Important Notes for Owners and Drivers After reading this manual, store it in the snowmobile for convenient reference. It should remain with the snowmobile when the snowmobile is sold. Follow the maintenance - 2007 Polaris 600 HO IQ | Owners Manual - Page 8
of our environment, including wildlife and vegetation. Snowmobile clubs and other organizations are working together to protect our environment. Please support their efforts and operate your snowmobile with consideration for the protection and preservation of our environment. Noise Level One of the - 2007 Polaris 600 HO IQ | Owners Manual - Page 9
symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for injury. WARNING The safety alert to the vehicle. NOTE A note will alert you to important information or instructions. 6 - 2007 Polaris 600 HO IQ | Owners Manual - Page 10
Operator Safety SAFETY Follow the recommended maintenance program beginning on page 82 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals. WARNING Driving a snowmobile requires your full - 2007 Polaris 600 HO IQ | Owners Manual - Page 11
while warming up the track. A loose track or flying debris could cause serious injury or death. We recommend having your dealer perform all track service and alignment procedures. Stay Clear of Engine Never attempt adjustments with the engine running. Turn off the ignition, raise the hood, make the - 2007 Polaris 600 HO IQ | Owners Manual - Page 12
Operator Safety Riding Position SAFETY Operating a snowmobile requires skill and balance for proper control. Rider positions may vary with experience and the features available on some snowmobiles, but under many conditions, the proper position is to be seated with both feet on the running boards - 2007 Polaris 600 HO IQ | Owners Manual - Page 13
your snowmobile at all times Spare Drive Belt Extra Set of Spark Plugs Tow Rope Extra Oil Fuel Deicer Winter Survival Kit Trail Map Owner's Manual First Aid Kit Tool Kit 10 - 2007 Polaris 600 HO IQ | Owners Manual - Page 14
Operator Safety Disabled Operators SAFETY Safe operation of this rider-active vehicle requires good judgement and physical skills. Operators with cognitive or physical disabilities have an increased risk of loss of control, which could result in serious injury or death. Rider Capacity Your - 2007 Polaris 600 HO IQ | Owners Manual - Page 15
SAFETY Operator Safety Driver Awareness Slow down when traveling near poles, posts, or other obstacles. Be especially alert if you're snowmobiling after dark. Always be on the alert for wire fences. Single strands are especially dangerous, since there may be a great distance between posts. Guy - 2007 Polaris 600 HO IQ | Owners Manual - Page 16
and avalanche conditions, contact local law enforcement in your area, or visit either the American Avalanche Association online at www.americanavalancheassociation.org or the U.S. Forest Service National Avalanche Center at www.avalanche.org. 13 - 2007 Polaris 600 HO IQ | Owners Manual - Page 17
may interfere with the steering of your machine, resulting in serious injury or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty - 2007 Polaris 600 HO IQ | Owners Manual - Page 18
Operator Safety Driving Downhill SAFETY When riding downhill, shift your weight to the rear of the machine and reduce your speed to a minimum. Apply just enough throttle to keep the clutch engaged, allowing the engine's compression to help slow the machine and keep it from rolling freely downhill. - 2007 Polaris 600 HO IQ | Owners Manual - Page 19
SAFETY Operator Safety Driving in Hilly Terrain WARNING Climbing a hill or crossing the face of a slope may result in loss of balance and machine roll-over, causing serious injury or death. Use caution and good judgement when driving in hilly terrain. Use extra caution when operating in hilly - 2007 Polaris 600 HO IQ | Owners Manual - Page 20
or filter removed. Damage to the engine may occur if the intake silencer or filter are removed. Clutches Do not attempt to service the clutches. All clutch service must be performed by your dealer. The clutch is a complex mechanism that rotates at high speeds. Each clutch is dynamically balanced - 2007 Polaris 600 HO IQ | Owners Manual - Page 21
SAFETY Operator Safety Inadequate Snow Conditions WARNING Do not drive for prolonged periods on blacktop, gravel, or ice. Doing so could cause irreversible track damage and lead to serious injury. Since snow provides the only lubrication for the power slide suspension and, on liquid cooled models - 2007 Polaris 600 HO IQ | Owners Manual - Page 22
Operator Safety Driving Responsibly SAFETY Every snowmobile handles differently, and even the most docile conditions may become dangerous if operators drive improperly. If you're new to snowmobiling, acquaint yourself with the machine and with what it will and won't do under various conditions. - 2007 Polaris 600 HO IQ | Owners Manual - Page 23
SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding. WINDCHILL CHART (_F) Wind Speed 40 in MPH Calm 5 10 15 20 25 30 35 40 45 50 55 60 40 36 34 32 30 29 28 28 27 26 26 25 25 Actual Thermometer - 2007 Polaris 600 HO IQ | Owners Manual - Page 24
of the decals depicted in this manual differ from the decals on your snowmobile, always read and follow the instructions of the decals on the snowmobile belt guard removed. Never run engine with drive belt removed. Never service clutches yourself -- see your dealer. Pressure Cap Warning This warning - 2007 Polaris 600 HO IQ | Owners Manual - Page 25
SAFETY Safety Decals and Locations Track Warning The track warning decal is on the rear of the tunnel: Stay clear of track. Do not sit on seat back. Entanglement with the track or a fall from seat back may result in severe injury or death. 9 "No Passenger" Warning The "NO PASSENGER" warning decal - 2007 Polaris 600 HO IQ | Owners Manual - Page 26
backing up. • Avoid sharp turns. • Shift to or from reverse only when stopped. • Apply throttle slowly. NOTE: For more information, see Owner's Manual. SAFETY 9 If electric reverse: • Machine stopped and engine at idle, push yellow button on LH control to reverse. Flashing light on dash indicates - 2007 Polaris 600 HO IQ | Owners Manual - Page 27
stop. • To maintain vehicle control on ice or hard-packed surfaces, you should have a proper balance of ski carbides to track studs. See Owner's Manual for proper use of traction products. • Repeated stops from high speed may cause fading or sudden loss of braking ability. • Parking brake may relax - 2007 Polaris 600 HO IQ | Owners Manual - Page 28
FEATURES 3 2 6 4 5 7 8 9 1 12 15 14 13 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. Hood Headlight Windshield Handlebar Seat Seat Storage Compartment Taillights Rear Bumper Snow Flap Suspension Track Console Storage Compartment (if equipped) Skis Nosepan Front Bumper 11 10 25 - 2007 Polaris 600 HO IQ | Owners Manual - Page 29
FEATURES 5 6 7 4 8 3 9 2 10 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. 14. 15. 16. 17. 1 Fuel Filler Cap RIDER SELECT (if equipped) 12 Ignition Switch Brake Lever Headlight Adjuster MFD Gauge Engine Stop Switch Throttle Control Hood Hold Down Straps Recoil Starter Handle Choke Lever Parking - 2007 Polaris 600 HO IQ | Owners Manual - Page 30
RIDER SELECT Adjustable Steering System FEATURES The RIDER SELECT adjustable steering system (if equipped) allows you to adjust the handlebar position to fit your style of riding. Setting Comfort Control Attack Position 1, 2 3, 4, 5 6, 7 Riding Style Pull the system rearward to one of the first - 2007 Polaris 600 HO IQ | Owners Manual - Page 31
FEATURES RIDER SELECT Adjustable Steering System WARNING Attempting to adjust the handlebar position while the snowmobile is moving could result in loss of control and serious injury or death. Always stop the snowmobile before attempting to adjust the steering system. 1. Stop the snowmobile. 2. - 2007 Polaris 600 HO IQ | Owners Manual - Page 32
Fuel Valve The fuel valve is located under the hood. Turn the fuel valve off whenever the snowmobile is stored or parked. 1. Turn the valve clockwise to turn off the fuel supply. 2. Turn the valve counter-clockwise to turn on the fuel supply. ON FEATURES OFF Seat Storage Compartment Open or close - 2007 Polaris 600 HO IQ | Owners Manual - Page 33
FEATURES Detonation Elimination Technology (D.E.T.) The DET system prevents damage to the engine from detonation while developing the maximum power of the engine safely. A detonation sensor monitors the engine and responds to detonation by automatically reducing the engine timing. This can result - 2007 Polaris 600 HO IQ | Owners Manual - Page 34
Detonation Elimination Technology (D.E.T.) DET Troubleshooting FEATURES Use this chart to determine causes and solutions for detonation. If none of these conditions exists and the sensor remains activated, see your Polaris - 2007 Polaris 600 HO IQ | Owners Manual - Page 35
Indicator 6 Brake Indicator 7 Reverse Indicator 8 High Beam Indicator 1 2 3 4 5 6 7 8 Digital Display Identification Item 1 RPM or Speed Altitude (if equipped) Service Interval 2 Electrical System Voltage Level 3 MAX - Maximum MPH/ KPH or RPM MPH -Miles per hour KPH - Kilometers per hour - 2007 Polaris 600 HO IQ | Owners Manual - Page 36
Instrumentation MFD Settings With the engine running, use the MFD Control Switch to set the MFD display to your preference. The rocker switch (9) has a MODE button (top) and a SET button (bottom). FEATURES Standard vs. Metric 9 The MFD will display either standard or metric units of measurement. - 2007 Polaris 600 HO IQ | Owners Manual - Page 37
FEATURES Instrumentation MFD Digital Display Programs Press the MODE button to cycle through the three MFD programs: Performance, Engine and History. Each program will remain in the display until another is selected. Performance Program While in the Performance mode, press the SET button to cycle - 2007 Polaris 600 HO IQ | Owners Manual - Page 38
Instrumentation MFD Digital Display Programs Trip Settings Trip 1 and Trip 2 are odometers used to check fuel mileage or to keep track of distance traveled. 1. To reset a trip odometer to zero, enter the Trip 1 or Trip 2 display. 2. Press and hold the SET button for two seconds. If the snowmobile is - 2007 Polaris 600 HO IQ | Owners Manual - Page 39
FEATURES Instrumentation MFD Digital Display Programs Engine Program The Engine Program automatically displays the engine coolant temperature, engine hours, electrical system voltage level and fuel level (if equipped). On machines equipped with altimeter sensor and ambient air temperature sensors, - 2007 Polaris 600 HO IQ | Owners Manual - Page 40
Instrumentation MFD Digital Display Programs Engine Program Altitude (if equipped) The rider can calibrate the altimeter for current atmospheric conditions. Altimeter accuracy will be +/-300 ft. (91 m) after adjustment. FEATURES NOTE: Press and hold the MODE switch for ten seconds to switch - 2007 Polaris 600 HO IQ | Owners Manual - Page 41
to view maximum vehicle speed, maximum engine rpm or the current service interval setting. The gauge automatically logs the maximum speed and engine Program will display the history of the Maximum Speed, Maximum RPM and Service Interval settings. Maximum Speed/RPM Reset While in either the MAX MPH - 2007 Polaris 600 HO IQ | Owners Manual - Page 42
"ENG" will flash in the icon area for five seconds each time the vehicle is started until the service reminder is reset. To reset the reminder at the existing interval: 1. Enter the service interval screen. 2. Press and hold the SET button for ten seconds, continuing to hold even after the display - 2007 Polaris 600 HO IQ | Owners Manual - Page 43
THE PERFECT FIT Front Suspension Adjustments Independent Front Suspension (IFS) Break in the suspension for about 150 miles (240 km) before making any fine-tuning adjustments. Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions. We - 2007 Polaris 600 HO IQ | Owners Manual - Page 44
, tool use, and shop procedures to perform the work safely and correctly. Shocks contain high-pressure nitrogen gas. Use extreme caution when handling high-pressure service equipment. We recommend that this work be performed by a Polaris dealer. 41 - 2007 Polaris 600 HO IQ | Owners Manual - Page 45
THE PERFECT FIT Front Suspension Adjustments Shock Compression Damping (if equipped) Turn the adjustment knob to make adjustments to the compression damping. The standard setting is 10 clicks from the full stop position. When adjusting, we recommend that you turn the knob only one click, then test - 2007 Polaris 600 HO IQ | Owners Manual - Page 46
Rear Suspension Adjustments THE PERFECT FIT Rider weight, riding style, trail conditions, and vehicle speed all affect suspension action. Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. However, all suspension designs - 2007 Polaris 600 HO IQ | Owners Manual - Page 47
THE PERFECT FIT Rear Suspension Adjustments Suspension Performance Tips • Rider weight usually determines the position at which the spring preload should be set. However, this may vary with riding style. With a little experimentation, each rider can find a preferred setup. These adjustments are - 2007 Polaris 600 HO IQ | Owners Manual - Page 48
Rear Suspension Adjustments To set up the rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement X. Take the first measurement with no rider and with the rear suspension at full extension. NOTE: The rear bumper may need to be lifted - 2007 Polaris 600 HO IQ | Owners Manual - Page 49
THE PERFECT FIT IQ Rear Suspension Adjustments Torsion Spring Preload To adjust rear torsion spring preload, rotate the three-position cam using the engine spark plug tool. Adjustment is easiest when the cam is rotated from low to medium, and then to high. Rotating directly from low to high will - 2007 Polaris 600 HO IQ | Owners Manual - Page 50
IQ Rear Suspension Adjustments THE PERFECT FIT Rear Shock Compression Damping (Premium Shocks) A B Turn 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, - 2007 Polaris 600 HO IQ | Owners Manual - Page 51
THE PERFECT FIT Suspension Coupling IQ Rear Suspension Adjustments On all Polaris snowmobile rear suspensions, there are two torque arms that control the movement of the rail beam. Prior to the advent of suspension coupling, these torque arms could move independently of each other. Rear suspension - 2007 Polaris 600 HO IQ | Owners Manual - Page 52
IQ Rear Suspension Adjustments THE PERFECT FIT Rear To Front Coupling and the Rear Rear Scissor Stop (RRSS) The rear rear scissor stop (RRSS) couples the movement of the rear torque arm with the front torque arm and limits the amount of independent movement between the rear torque and the front - 2007 Polaris 600 HO IQ | Owners Manual - Page 53
weight transfer or ski lift during acceleration, rotate the RRSS to a lower position. NOTE: Your dealer can help you with initial setup and additional setup instructions to help you achieve your optimum ride. A scissor stop tool is also available from your dealer. HIGH LOW LOW MEDIUM 50 - 2007 Polaris 600 HO IQ | Owners Manual - Page 54
SwitchBack Rear Suspension Adjustments Torsion Spring Preload THE PERFECT FIT To adjust rear torsion spring preload, rotate the three-position cam using the engine spark plug tool. Different rate torsion springs are available if a firmer ride is desired. Contact your dealer for more information. - 2007 Polaris 600 HO IQ | Owners Manual - Page 55
THE PERFECT FIT SwitchBack Rear Suspension Adjustments Rear Shock Compression Damping Turn 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. - 2007 Polaris 600 HO IQ | Owners Manual - Page 56
: brakes, clutches, fuel systems, and exhaust systems. • Exhaust systems are critical safety areas that must use approved Polaris parts. Please see your Polaris dealer for service. 53 - 2007 Polaris 600 HO IQ | Owners Manual - Page 57
THE PERFECT FIT Handlebar Adjustments When making handlebar adjustments, always be sure the handlebars, brake lever and throttle lever operate smoothly and do not contact the fuel tank, windshield or any other part of the vehicle when the handlebars are turned fully to the left or right. Handlebar - 2007 Polaris 600 HO IQ | Owners Manual - Page 58
Handlebar Adjustments Handlebar Position THE PERFECT FIT If your snowmobile is equipped with the RIDER SELECT feature, adjust handlebar position as outlined on page 27. For models with stationary steering posts, adjust handlebar position as outlined below. Refer to the illustration on page 54. 1. - 2007 Polaris 600 HO IQ | Owners Manual - Page 59
THE PERFECT FIT Traction Products Studs Before equipping your machine with traction products, be aware of the laws in your area pertaining to the use of traction products. Use only Polaris traction products on your snowmobile. Track warranties are void if track damage or failure results from - 2007 Polaris 600 HO IQ | Owners Manual - Page 60
Traction Products nCarbide Skags THE PERFECT FIT A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain. Use carbide skags with studded tracks to help maintain proper vehicle - 2007 Polaris 600 HO IQ | Owners Manual - Page 61
PRE-RIDE INSPECTIONS Pre-Ride Checklist Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined on the referenced pages. Look for a checkmark (n) on the referenced pages to locate the pre-ride inspection items. Item Drive Belt - 2007 Polaris 600 HO IQ | Owners Manual - Page 62
and Understand Your Owner's Manual Read the Owner's Manual completely and refer to it often. The manual is your guide to safe and enjoyable lever freeplay, DO NOT start the engine. Have the throttle serviced immediately. n Throttle Safety Switch Test the throttle safety switch system before - 2007 Polaris 600 HO IQ | Owners Manual - Page 63
indicates low brake fluid level or air in the hydraulic system. Refer to the brake bleeding information on page 103 or see your dealer for service. 1/2I (1.3 cm) Lever Feel If the brake lever feels "spongy" when squeezed, check the brake fluid level and condition. Add fluid as needed. See page - 2007 Polaris 600 HO IQ | Owners Manual - Page 64
is in use. If the parking brake light does not come on when the parking brake or service brake is in use, have it serviced by your dealer. Lock Release To release the lock, squeeze the brake lever tightly. The lock will return to the unlock position. WARNING If the - 2007 Polaris 600 HO IQ | Owners Manual - Page 65
may interfere with the steering of your machine, resulting in serious injury or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty - 2007 Polaris 600 HO IQ | Owners Manual - Page 66
Before Starting the Engine n Hood Latches PRE-RIDE INSPECTIONS The hood of the snowmobile protects the operator from moving parts as well as aiding in sound emission control and other functions. Under no circumstances should your snowmobile be operated with the hood open or removed. Always ensure - 2007 Polaris 600 HO IQ | Owners Manual - Page 67
PRE-RIDE INSPECTIONS n Engine Stop Switch Start the Engine and Check Check the auxiliary shut-off 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 stops when the ignition switch is turned to OFF. n Tether - 2007 Polaris 600 HO IQ | Owners Manual - Page 68
Starting the Engine WARNING OPERATION Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start your snowmobile without checking all components to be sure of proper operation. See Before Starting the Engine beginning on page 59. Starting a - 2007 Polaris 600 HO IQ | Owners Manual - Page 69
cranking the engine. When the engine starts, immediately release the throttle. 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 oil - 2007 Polaris 600 HO IQ | Owners Manual - Page 70
Engine Break-In Oil Injection System OPERATION Always check and fill the oil tank when refueling. See page 71. CAUTION Serious engine damage can occur without the proper lubrication. Check the oil tank level often during the first tank of fuel. If the oil level doesn't go down, contact your - 2007 Polaris 600 HO IQ | Owners Manual - Page 71
behind it while warming up the track. Do not use excessive throttle during warm-up or when the track is free-hanging. Use a stable rear support. WARNING Use of traction products such as studs, ice growsers, etc. will increase the possibility of track damage and/or failure. This could cause loss - 2007 Polaris 600 HO IQ | Owners Manual - Page 72
Fuel WARNING OPERATION Gasoline is highly flammable and explosive under certain conditions. Always exercise extreme caution whenever handling gasoline. Always refuel outdoors or in a well-ventilated area. Always turn off the engine before refueling. Do not overfill the tank. Do not fill the tank - 2007 Polaris 600 HO IQ | Owners Manual - Page 73
OPERATION Fuel For peak performance, Polaris recommends the use of 91 octane or higher fuel. Although 87 octane fuel is usable, some engine performance will be lost and fuel economy will decrease. Do not use lower than 87 octane fuel. Do not use fuel containing more than 10% ethanol (including E85). - 2007 Polaris 600 HO IQ | Owners Manual - Page 74
Oil n Low Oil Indicator Light OPERATION The low oil indicator light will alert the operator if the oil level is low. Visually check for oil in the bottle. Add oil before further operation of the snowmobile. See page 67 for oil recommendations. n Low Oil Level Maintaining the proper oil level will - 2007 Polaris 600 HO IQ | Owners Manual - Page 75
OPERATION Carburetion Proper carburetor adjustment is critical. A lean mixture (too much air, too little fuel) may result in piston burning, bearing failure, or complete engine failure. A rich mixture (too much fuel, too little air) may foul plugs and cause generally poor engine performance. A lean - 2007 Polaris 600 HO IQ | Owners Manual - Page 76
and may cause serious engine damage. Jet the carburetors carefully for elevation and temperature according to the jetting charts in your Owner's Manual Supplement. NOTE: It's the owner's responsibility to ensure that the correct jets are installed in the machine for a geographical area. Be very - 2007 Polaris 600 HO IQ | Owners Manual - Page 77
OPERATION n Engine Stop Switch Push down on the engine stop switch (9) to ground out the ignition and stop the engine quickly. Pull the switch up to the ON position to allow restarting. 9 n Throttle Safety Switch The throttle safety switch is designed to stop the engine whenever all pressure is - 2007 Polaris 600 HO IQ | Owners Manual - Page 78
may cause the safety switch to activate, preventing the engine from starting. If this occurs, return the machine to an authorized Polaris dealer for service. If an emergency exists and it's necessary to start the engine, the throttle safety switch and engine stop switch may be disconnected from the - 2007 Polaris 600 HO IQ | Owners Manual - Page 79
OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 74 for more information about the engine stop switch and throttle safety switch. SYSTEM Ignition Switch Brake Choke Engine Stop Switch Throttle Safety Switch Tether - 2007 Polaris 600 HO IQ | Owners Manual - Page 80
Emergency Starting 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. 4. Starting at one of the tower struts, wind the strap counterclockwise around the clutch as shown. OPERATION If the recoil starter - 2007 Polaris 600 HO IQ | Owners Manual - Page 81
OPERATION Electronic Reverse (PERCt) Electronic reverse will activate only if the engine RPM is below 4000. WARNING Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Damage will occur to the chaincase or transmission if shifting is - 2007 Polaris 600 HO IQ | Owners Manual - Page 82
Daily Storage At the end of each ride, park the snowmobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4I (10 cm) off the ground. Remove the key and - 2007 Polaris 600 HO IQ | Owners Manual - Page 83
and it comes on, you must take your snowmobile to a qualified dealer for diagnostic service. Specifications and adjustments for engine tune-ups are located in the Service Manual, which is available to your qualified service technician. Reverse (if equipped) must not be engaged during engine tune-ups - 2007 Polaris 600 HO IQ | Owners Manual - Page 84
specified maintenance is performed, including the emission-related maintenance outlined in these sections of the manual. You must inspect the air intake system on your snowmobile prior to each use ( that you contact an authorized Polaris dealer to perform any service that may be necessary. 81 - 2007 Polaris 600 HO IQ | Owners Manual - Page 85
MAINTENANCE Polaris Recommended Maintenance Program To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as outlined in this manual. Record maintenance and service in the Maintenance Log beginning on page 138. The recommended - 2007 Polaris 600 HO IQ | Owners Manual - Page 86
Periodic Maintenance Interval Table MAINTENANCE The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. When inspection reveals the need for replacement parts, always use - 2007 Polaris 600 HO IQ | Owners Manual - Page 87
MAINTENANCE Item Periodic Maintenance Interval Table See Page Frequency 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi. (3200 km) PreSeason BRAKES Hose Routing Hose Condition Fluid Leaks Brake Pads Brake Disc Parking Brake Brake System Brake Fluid Pilot Air Screws Carburetor ( - 2007 Polaris 600 HO IQ | Owners Manual - Page 88
Periodic Maintenance Interval Table Item See Page 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) MAINTENANCE 2000 mi. (3200 km) PreSeason Frequency CHASSIS Ski Toe Alignment Suspension Mounting Bolts Steering Fasteners Rear Suspension Fasteners Suspension Shock Oil Cooling Fins and Shroud - 2007 Polaris 600 HO IQ | Owners Manual - Page 89
MAINTENANCE Lubrication Front Suspension Lubricate the steering post U-joint (with engine fogging oil at the intervals outlined in the maintenance charts beginning on page 82. Lubricate the U-joint after seasonal storage as well as before seasonal storage. See page 122 for the part numbers of - 2007 Polaris 600 HO IQ | Owners Manual - Page 90
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 pumps. Do not use more than four pumps. 9 MAINTENANCE Throttle Cable Lubricate the throttle cable - 2007 Polaris 600 HO IQ | Owners Manual - Page 91
MAINTENANCE Lubrication n Chaincase Oil Check the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 82. 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). Change the - 2007 Polaris 600 HO IQ | Owners Manual - Page 92
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. MAINTENANCE 4 4. Install a new sealing washer on the drain plug. NOTE - 2007 Polaris 600 HO IQ | Owners Manual - Page 93
the engine is operated in conditions more severe than intended for that plug. Always use the spark plugs recommended for your snowmobile. See your Owner's Manual Supplement Use recommended spark plugs with the proper gap. Use only resistor-type spark plugs. Torque spark plugs to 18-22 ft. lbs. (24 - 2007 Polaris 600 HO IQ | Owners Manual - Page 94
correct main jet is installed in the carburetor(s). Refer to the Owner's Manual Supplement or see your dealer. 1. Normal The normal insulator tip is gray This indicates the proper type and heat range for the engine and the service. NOTE: The tip should not be white. A white insulator tip indicates - 2007 Polaris 600 HO IQ | Owners Manual - Page 95
MAINTENANCE Spark Plug Removal and Replacement 1. Remove the spark plug cap. 2. Using the special wrench provided in the tool pouch, rotate the spark plug counterclockwise to remove. 3. Reverse the procedure for spark plug installation. 4. Torque to 18-22 ft. lbs. (24-30 Nm). 5. Reinstall the spark - 2007 Polaris 600 HO IQ | Owners Manual - Page 96
or carburetor malfunction. Always reinstall the intake filters before operating the snowmobile. Fuel Pump All fuel pump service must be performed by an authorized Polaris dealer. Do not attempt to service the fuel pump. Fuel Filter/Fuel Lines See your Polaris dealer for replacement of the in-tank - 2007 Polaris 600 HO IQ | Owners Manual - Page 97
MAINTENANCE Carburetor The number stamped in the end of the main jet indicates the jet size. The jet installed at the time of manufacture is not necessarily correct for your elevation. It's your dealer's responsibility to make sure the correct main jet is installed. CAUTION Operating the snowmobile - 2007 Polaris 600 HO IQ | Owners Manual - Page 98
occur. Always work in a well ventilated area away from anything that may cause the fuel to ignite, such as open flames, sparks, heaters, trouble lights, cigarettes, etc. Review the fuel warnings on page 69. Cleaning Procedure 1. Turn the fuel valve off. 2. Place a container or shop towels below - 2007 Polaris 600 HO IQ | Owners Manual - Page 99
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 operated at extremely low temperatures, greater - 2007 Polaris 600 HO IQ | Owners Manual - Page 100
coolant maintains its ability to protect the engine, drain the system completely every two years and add a fresh mixture of antifreeze and distilled water. This service must be performed when the engine is cold. Ask your Polaris dealer to check the coolant when he performs the fall tune-up on your - 2007 Polaris 600 HO IQ | Owners Manual - Page 101
MAINTENANCE Cooling System Bleeding the Cooling System WARNING Steam and hot liquids will cause serious burns to your skin. Never bleed the cooling system or remove the pressure cap when the engine is warm or hot. Use of a non-standard pressure cap will not allow the recovery system to function - 2007 Polaris 600 HO IQ | Owners Manual - Page 102
the engine running. 1. Open the hood and inspect the muffler and pipes for cracks or damage. 2. Check for weak or missing retaining springs or damper/support grommets. 3. Check for loose clamps on the pipe covers. 99 - 2007 Polaris 600 HO IQ | Owners Manual - Page 103
MAINTENANCE Drive Chain Tension Check drive chain tension weekly and before each long trip. To obtain correct chain tension: 1. Rotate the driven clutch counterclockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly. 2. - 2007 Polaris 600 HO IQ | Owners Manual - Page 104
Brakes n Hydraulic Brake Inspection MAINTENANCE Inspect brake lever travel before each use of the snowmobile. See page 60. Brake pads must be replaced when the brake pad material becomes thinner than the backing plate (approximately 1/16I). A kit is available for replacing brake pads. See your - 2007 Polaris 600 HO IQ | Owners Manual - Page 105
MAINTENANCE Brakes Brake Fluid The brake fluid level can be seen through a plastic sight glass in the brake reservoir. If the fluid is sufficient, 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 - 2007 Polaris 600 HO IQ | Owners Manual - Page 106
Brakes MAINTENANCE Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action. Bleed the system before operating the snowmobile. WARNING Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an accident and - 2007 Polaris 600 HO IQ | Owners Manual - Page 107
MAINTENANCE Lights NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do touch the bulb, clean it with an alcoholmoistened towel. Headlight Bulb Removal 1. Remove the plenum covering from the - 2007 Polaris 600 HO IQ | Owners Manual - Page 108
Lights Taillight/Brakelight Replacement 600 HO IQ 1. Open the rear storage compartment. 2. Reach into the compartment and locate the socket assembly above the door opening. 3. Turn the socket counterclockwise 1/4 turn. 4. Carefully pull the socket assembly away from the taillight. MAINTENANCE 5. - 2007 Polaris 600 HO IQ | Owners Manual - Page 109
alignment offset is important for maintaining optimum performance. See your dealer for service and adjustments. A special tool is required to check for proper alignment. Clutch Center Distance See your Owner's Manual Supplement for recommended center distance for your machine. If adjustment is - 2007 Polaris 600 HO IQ | Owners Manual - Page 110
excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions exist. See Drive Belt Troubleshooting on page 128. For improved drive-away during extremely cold temperatures, remove the belt and warm it to room temperature. Reinstall it before - 2007 Polaris 600 HO IQ | Owners Manual - Page 111
MAINTENANCE Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. NOTE: To ensure satisfactory belt life, install belts so they operate in the same direction of rotation by positioning the identification numbers so that you can read them. If - 2007 Polaris 600 HO IQ | Owners Manual - Page 112
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 be 1 1/4I (3.2 cm). MAINTENANCE 1 2 Drive Belt - 2007 Polaris 600 HO IQ | Owners Manual - Page 113
, arrange for a fall service tune-up with your Polaris dealer. His experienced and trained service technician will keep your machine . Never rotate a damaged track under power. 1. Using a hoist, safely lift and support the rear of the snowmobile off the ground. 2. Rotate the track by hand to - 2007 Polaris 600 HO IQ | Owners Manual - Page 114
Track Maintenance Track Lubrication MAINTENANCE WARNING Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure, loss of vehicle control and loss of braking ability, which can result in serious injury or death. Avoid operating for - 2007 Polaris 600 HO IQ | Owners Manual - Page 115
adjustments should be made only after the track is warmed up and limber. 1. Turn the engine off. 2. Lift the rear of the machine and safely support it off the ground. 3. Place the recommended weight or downward pressure on the track at the specified distance (see chart) ahead of the center of - 2007 Polaris 600 HO IQ | Owners Manual - Page 116
Track Maintenance Track Tension MAINTENANCE 4. Check for specified slack between the wear surface of the track clip and the plastic slider. Refer to the Track Tension Data Chart on page 112. If the track needs adjustment: 5. Loosen the rear idler shaft bolt. 6. Loosen the locknuts. Adjusting Screw - 2007 Polaris 600 HO IQ | Owners Manual - Page 117
check that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. 1. Safely support the rear of the machine with the track off the ground. 2. Start the engine and apply a small amount of throttle until the track turns slowly - 2007 Polaris 600 HO IQ | Owners Manual - Page 118
Steering System Steering Inspection and Adjustment MAINTENANCE Each week, or before a long ride, check all steering system fasteners and tighten if necessary. 9 9 9 9 9 115 - 2007 Polaris 600 HO IQ | Owners Manual - Page 119
MAINTENANCE Steering System Ski Alignment WARNING Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski alignment or camber adjustment. See your Polaris dealer. With the handlebars in a straight ahead - 2007 Polaris 600 HO IQ | Owners Manual - Page 120
when worn to half their original diameter. NOTE: Carbide skags must be replaced if any abnormal wear or chipping is found. Skag Replacement 1. Raise and support the front of the machine so the skis are approximately 6I (15.2 cm) from the ground. 2. Remove the attaching nuts and pry the skag - 2007 Polaris 600 HO IQ | Owners Manual - Page 121
reduce your snowmobile's reliability and cause needless repairs and down time. Before beginning any snowmobile trip, a visual inspection will uncover potential problems. Check the following items on a weekly basis or before any long trip: n Check suspension mounting bolts for tightness. n Check rear - 2007 Polaris 600 HO IQ | Owners Manual - Page 122
Extended Storage MAINTENANCE Off-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components. See page 122 for the part numbers of Polaris products. Cleaning and Preservation Proper storage starts with - 2007 Polaris 600 HO IQ | Owners Manual - Page 123
except the driven clutch shaft bushing as outlined in the Master Repair Manual. See your dealer. Engine and Carburetor Protection Proper preparation of the be fogged with fogging oil. Follow the engine fogging instructions provided on the container. Always add Premium Carbon Clean or a fuel - 2007 Polaris 600 HO IQ | Owners Manual - Page 124
moving parts, and hot exhaust parts. Track and Suspension Moderate track tension should be maintained during summer storage. The machine should be supported off the ground to allow the track to hang freely. Transporting the Snowmobile Whenever the snowmobile is transported: 1. Turn the fuel valve - 2007 Polaris 600 HO IQ | Owners Manual - Page 125
POLARIS PRODUCTS Part No. 2870791 2871098 2871097 2871240 2871721 2871722 2872347 2874438 2874439 2874443 2873105 2872951 2871312 2871322 2871423 2871329 2871323 2871534 2871326 2870652 2872189 2872893 2870505 2872889 2872890 Description Engine Lubricants Fogging Oil (12 oz. Aerosol) Premium 2- - 2007 Polaris 600 HO IQ | Owners Manual - Page 126
Engine Troubleshooting TROUBLESHOOTING Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Erratic engine operating RPM during acceleration or load variations Harsh drive clutch engagement Probable Cause Solution Drive clutch - 2007 Polaris 600 HO IQ | Owners Manual - Page 127
TROUBLESHOOTING Problem Noise in drive system Engine Troubleshooting Probable Cause Solution Broken drive clutch components Bearing failure/ chaincase, jackshaft, or front drive shaft Drive belt surface flat spots Drive chain loose Drive chain - 2007 Polaris 600 HO IQ | Owners Manual - Page 128
Engine Troubleshooting Problem Engine turns but fails to start Faulty ignition TROUBLESHOOTING Probable Cause Solution too small will cause seizure resulting in loss of power. This indicates a major engine problem that must be repaired before operating. SEE YOUR DEALER. • Replace the plug(s). • - 2007 Polaris 600 HO IQ | Owners Manual - Page 129
TROUBLESHOOTING Problem Rear suspension bottoms too easily IQ Suspension Troubleshooting Solution • Adjust torsion spring preload to achieve proper static sag (see page 45). • Change torsion spring to stiffer optional spring (see your dealer). • Revalve rear - 2007 Polaris 600 HO IQ | Owners Manual - Page 130
SwitchBack Suspension Troubleshooting Problem Rear suspension bottoms too easily TROUBLESHOOTING Solution • Set static sag (see page 45). Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions. • Increase shock compression damping ( - 2007 Polaris 600 HO IQ | Owners Manual - Page 131
Drive Belt Troubleshooting Belt Wear/Burn Diagnosis Causes Driving at low RPM Insufficient warm-up Solutions • Drive at higher RPMs. Gear the machine down. Check belt deflection. • Warm - 2007 Polaris 600 HO IQ | Owners Manual - Page 132
of purchase 5. Details of trouble experienced 6. Length of time and conditions of operation 7. Previous correspondence Use the page provided near the front of your Owner's Manual to record the identification numbers of your snowmobile and its engine. Polaris Customer Service United States: 1-763-417 - 2007 Polaris 600 HO IQ | Owners Manual - Page 133
1. Polaris snowmobile owner reports theft. A. In addition to notifying the proper law enforcement officials, the owner must call Polaris Customer Service. B. Owners must provide their name, address, telephone number and the model and serial number of stolen machines. 2. 3. Polaris warranty will - 2007 Polaris 600 HO IQ | Owners Manual - Page 134
preparation and setup of your snowmobile is very important in ensuring trouble-free operation. Purchasing a snowmobile in the crate or without any damages that occur during trailer transit or as a result of unauthorized service or parts. In addition, this warranty does not cover physical damage to - 2007 Polaris 600 HO IQ | Owners Manual - Page 135
dealer is YOUR responsibility). Polaris recommends that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service. Please work with your dealer to resolve any warranty issues. Your dealer will contact the appropriate personnel at Polaris if - 2007 Polaris 600 HO IQ | Owners Manual - Page 136
to perform the required vehicle Pre-Delivery Inspection, perform all applicable service bulletins and have the consumer sign the PDI form prior to delivery products for lubrication and maintenance as directed by the Owner's manual is highly recommended. Should a failure occur during the warranty - 2007 Polaris 600 HO IQ | Owners Manual - Page 137
oil. • Piston seizures, unless caused by a defective engine component. • Failures caused due to improper adjustments. • Failure due to unauthorized service. • Failures due to lack of service as required in the owner's manual or Polaris updates. This includes off-season storage as listed in the owner - 2007 Polaris 600 HO IQ | Owners Manual - Page 138
must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle. Outside the Country where your vehicle - 2007 Polaris 600 HO IQ | Owners Manual - Page 139
WARRANTY Snowmobile Engine Emissions Limited Warranty This snowmobile engine emissions limited warranty is in addition to the Polaris standard limited warranty for snowmobiles. Polaris Industries Inc. warrants that the new engine, including all parts of its emissioncontrol system, is designed, - 2007 Polaris 600 HO IQ | Owners Manual - Page 140
for performing the scheduled maintenance identified in the owner's manual. Polaris can deny an emissions warranty claim if any snowmobile. Polaris recommends that you contact an authorized Polaris dealer to perform any service that may be necessary. It is a potential violation of the Clean Air - 2007 Polaris 600 HO IQ | Owners Manual - Page 141
LOG Present this section of your manual to your dealer each time your snowmobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 150 mi. (240 km - 2007 Polaris 600 HO IQ | Owners Manual - Page 142
MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 139 - 2007 Polaris 600 HO IQ | Owners Manual - Page 143
Belt Installation ...108 Drive Belt Removal ...107 Drive Belt Troubleshooting ...128 Drive Chain Tension ...100 Driver Awareness ...12 ...96-98 Cooling System, Bleeding ...98 Cooling System, Flushing ...97 Customer Service...129 F Front Rear Scissor Stop ...48 Front Suspension Adjustments . . 40- - 2007 Polaris 600 HO IQ | Owners Manual - Page 144
INDEX I IFS Components ...40 Inadequate Snow Conditions ...18 Instrumentation ...32-39 Intake Filters ...93 Intake Silencer ...17 R Rear Shocks, SwitchBack ...52 Rear Suspension Adjustments . . 43-52 Rear Suspension Adjustments IQ ...46-50 SwitchBack ...51-52 Rear To Front Coupling ...49 Recoil - 2007 Polaris 600 HO IQ | Owners Manual - Page 145
...86 T Track Tension ...44, 112 Track Warm-Up...68 Track Warning...22 Traction Products...56-57 Transporting the Snowmobile ...121 Troubleshooting Drive Belt ...128 Engine ...123-125 IQ Rear Suspension ...126 SwitchBack Rear Suspension . 127 Tune-Up...110 T Taillight/Brakelight Replacement
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