2006 Polaris 600 Switchback Owners Manual

2006 Polaris 600 Switchback Manual

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  • 2006 Polaris 600 Switchback | Owners Manual - Page 1
  • 2006 Polaris 600 Switchback | Owners Manual - Page 2
  • 2006 Polaris 600 Switchback | 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. PROPOSITION 65 WARNING Snowmobile engines discharge fuel
  • 2006 Polaris 600 Switchback | 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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 5
    or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A. 2006 600 RMK/Switchback Owner's Manual P/N 9920058 2
  • 2006 Polaris 600 Switchback | Owners Manual - Page 6
    of important identification numbers that should be recorded in the owner's manual. This section describes safe vehicle operation and identifies warning decals . Operation ...57 Maintenance ...70 Polaris Products ...Troubleshooting ...Warranty ...Maintenance Log ...Index ...108 109 114 120 122 3
  • 2006 Polaris 600 Switchback | Owners Manual - Page 7
    4
  • 2006 Polaris 600 Switchback | Owners Manual - Page 8
    with the snowmobile when sold. Some of the illustrations and photos used in this manual are general representations. Your model may differ. Follow the maintenance program outlined in this manual. Preventive maintenance ensures that critical components of the snowmobile are inspected by your dealer
  • 2006 Polaris 600 Switchback | Owners Manual - Page 9
    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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 10
    Vehicle Identification Numbers INTRODUCTION Record your snowmobile's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are
  • 2006 Polaris 600 Switchback | Owners Manual - Page 11
    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. 8
  • 2006 Polaris 600 Switchback | Owners Manual - Page 12
    Operator Safety SAFETY Follow the recommended maintenance program outlined beginning on page 70 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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 13
    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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 14
    your snowmobile at all times: SSpare Drive Belt SExtra Set of Spark Plugs STow Rope SExtra Oil SFuel Deicer SWinter Survival Kit STrail Map SOwner's Manual SFirst Aid Kit STool Kit Riding Apparel Be prepared, be warm and be comfortable when riding. Be aware of the weather forecast, especially the
  • 2006 Polaris 600 Switchback | Owners Manual - Page 15
    SAFETY Operator Safety Disabled Operators 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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 16
    Operator Safety Driver Awareness SAFETY 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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 17
    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. 14
  • 2006 Polaris 600 Switchback | Owners Manual - Page 18
    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
  • 2006 Polaris 600 Switchback | 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
  • 2006 Polaris 600 Switchback | 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
  • 2006 Polaris 600 Switchback | 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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 22
    Operator Safety SAFETY Driving Responsibly 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.
  • 2006 Polaris 600 Switchback | 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. WIND CHILL CHART (°F) Wind Speed in MPH 40 35 30 25 20 15 Actual Thermometer Reading (°F) 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40
  • 2006 Polaris 600 Switchback | Owners Manual - Page 24
    of the decals and other warnings on the snowmobile carefully. If any 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. If any decal becomes illegible or comes off, contact your Polaris dealer
  • 2006 Polaris 600 Switchback | Owners Manual - Page 25
    SAFETY Safety Decals and Locations Track Warning + Warming 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. "No Passenger" Warning Warming This vehicle is designed for operator only. "NO PASSENGER" + 22
  • 2006 Polaris 600 Switchback | Owners Manual - Page 26
    and while backing. Avoid sharp turns. Shift to or from reverse only when stopped. Apply throttle slowly. NOTE: For more information, see Owner's Manual. If electric reverse: S Machine stopped and engine at idle, push yellow button on LH S Push button again to return to forward. S Elevation setting
  • 2006 Polaris 600 Switchback | Owners Manual - Page 27
    stop. S 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. S Repeated stops from high speed may cause fading or sudden loss of braking ability. S Parking brake may relax
  • 2006 Polaris 600 Switchback | Owners Manual - Page 28
    1. 2. 3. 4. 5. 6. 7. 8. Hood Headlight Windshield Handlebar Side Shield Seat Storage Compartment Taillights 9. 10. 11. 12. 13. 14. 15. Rear Bumper Snow Flap Suspension Track Nosepan Front Bumper Ski FEATURES 3 4 5 6 7 8 9 2 1 7 10 12 11 15 14 13 1. 2. 3. 4. 5. 6. 7. 8. 9. Fuel
  • 2006 Polaris 600 Switchback | Owners Manual - Page 29
    FEATURES RIDER SELECT Adjustable Steering System The RIDER SELECT adjustable steering system allows you to adjust the handlebar position to fit your style of riding. Choosing the Best RIDER SELECTt Position Position 1 2 3 Riding Style Relaxed Trail Riding Rider weight is slightly behind the
  • 2006 Polaris 600 Switchback | Owners Manual - Page 30
    RIDER SELECT Adjustable Steering System FEATURES 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.
  • 2006 Polaris 600 Switchback | Owners Manual - Page 31
    FEATURES 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. 1 2 Seat Storage Compartment Lift the seat
  • 2006 Polaris 600 Switchback | Owners Manual - Page 32
    retards timing and holds it in a retarded state. The DET light will remain on until the engine is turned off and restarted. DET Troubleshooting Use this chart to determine causes and solutions for detonation. If none of these conditions exists and the sensor remains activated, see your Polaris
  • 2006 Polaris 600 Switchback | Owners Manual - Page 33
    Temp Indicator 6 Brake Indicator 7 Reverse Indicator 8 High Beam Indicator 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 RPM
  • 2006 Polaris 600 Switchback | Owners Manual - Page 34
    Instrumentation MFD Settings FEATURES With the engine running, use the MFD Control Switch (1) to set the 1 MFD display to your preference. The rocker switch has a MODE button (2) and a SET button (3). Standard vs. Metric The MFD will display either standard or metric units of 2 measurement. While
  • 2006 Polaris 600 Switchback | Owners Manual - Page 35
    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. NOTE: The analog will always display either MPH or engine RPM (whichever setting
  • 2006 Polaris 600 Switchback | Owners Manual - Page 36
    Instrumentation FEATURES MFD Digital Display Programs Performance 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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 37
    FEATURES Instrumentation MFD Digital Display Programs Altitude (if equipped) The rider can calibrate the altimeter for current atmospheric conditions. Altimeter accuracy will be +/-300 ft. (91 m) after adjustment. NOTE: Press and hold the MODE switch for ten seconds to switch between standard and
  • 2006 Polaris 600 Switchback | Owners Manual - Page 38
    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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 39
    "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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 40
    Instrumentation FEATURES MFD Battery Replacement If the clock function of the MFD isn't 1 working properly, replace the battery. Replacement batteries are available from your dealer. 1. Remove the plenum from the underside of the hood. 2. Locate the black battery 2 compartment (1). It has a red
  • 2006 Polaris 600 Switchback | Owners Manual - Page 41
    FEATURES Instrumentation Gauge Cleaning 1. Wipe the gauge face as needed using a clean cloth and a mild soap and water solution. Wipe dry with clean, soft cloth. 2. Clean the back side of the gauge using a clean cloth and a mild soap and water solution. Do not remove the electrical connectors or
  • 2006 Polaris 600 Switchback | Owners Manual - Page 42
    IQ Front Suspension Adjustments Independent Front Suspension (IFS) THE PERFECT FIT Break in the suspension for approximately 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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 43
    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. Front Springs The front springs can be changed if spring preload
  • 2006 Polaris 600 Switchback | Owners Manual - Page 44
    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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 45
    THE PERFECT FIT Rear Suspension Adjustments Rear Suspension Initial Spring Preload Setting (Sag Method) To set up the rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement X. Take this measurement with no rider and with the rear
  • 2006 Polaris 600 Switchback | Owners Manual - Page 46
    Rear Suspension Adjustments Rear Torsion Spring Tension THE PERFECT FIT To adjust rear torsion spring tension, 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. The
  • 2006 Polaris 600 Switchback | Owners Manual - Page 47
    THE PERFECT FIT Rear Shocks Rear Suspension Adjustments Indy Select Rear Shock Some snowmobiles are equipped with the Indy Select rear shock, which allows for adjustments to the compression valving by turning the adjustment screw located near the base of the shock. Locate the adjustment screw (L)
  • 2006 Polaris 600 Switchback | Owners Manual - Page 48
    Rear Suspension Adjustments Rear Shocks THE PERFECT FIT ARVIN Rapid Adjust Shock The ARVIN Rapid Adjust shock is available as an option on some models. Turn the Rapid Adjust knob (L) on the shock reservoir to make adjustments to the compression damping. Positions are labeled on the shock. When
  • 2006 Polaris 600 Switchback | Owners Manual - Page 49
    THE PERFECT FIT Handlebar Position Handlebar Adjustments Use the RIDER SELECT feature to adjust handlebar position. See page 26. Handlebar Angle Follow these steps to adjust handlebar angle at the handlebar block. 1. Remove the handlebar cover (1) to expose the handlebar and the four adjuster
  • 2006 Polaris 600 Switchback | Owners Manual - Page 50
    , clutches, fuel systems, and exhaust systems. NOTE: Exhaust systems are critical safety areas that must use approved Polaris parts. Please see your Polaris dealer for service. 47
  • 2006 Polaris 600 Switchback | Owners Manual - Page 51
    THE PERFECT FIT Studs Traction Products (SwitchBack only) 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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 52
    Traction Products (SwitchBack only) n Carbide 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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 53
    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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 54
    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 excessive lever freeplay, DO NOT start the engine. Have the throttle serviced immediately. n Throttle Safety Switch Test the throttle safety switch system
  • 2006 Polaris 600 Switchback | Owners Manual - Page 55
    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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 56
    needed. See page 89. Check for the presence of air in the fluid system. See page 90 for more information, or see your dealer for service. WARNING Continued use of "spongy" brakes may cause a complete loss of brakes, which could result in serious injury or death. Always have the brakes
  • 2006 Polaris 600 Switchback | Owners Manual - Page 57
    is in use. If the park brake light does not come on when the park 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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 58
    Before Starting the Engine n Track PRE-RIDE INSPECTIONS WARNING Operating the snowmobile with a damaged track increases the possibility of track failure, which could cause loss of control resulting in serious injury or death. Always inspect the track for damage before using the vehicle. Use of
  • 2006 Polaris 600 Switchback | Owners Manual - Page 59
    PRE-RIDE INSPECTIONS Start the Engine and Check n Engine Stop Switch 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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 60
    Starting the Engine OPERATION WARNING 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 Check Before Starting the Engine beginning on page 51. Starting
  • 2006 Polaris 600 Switchback | Owners Manual - Page 61
    your right hand. 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 gasoline with one pint of Polaris injection oil
  • 2006 Polaris 600 Switchback | Owners Manual - Page 62
    Engine Break-In OPERATION Oil Injection System Always fill the oil tank when refueling. See page 63. 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 dealer
  • 2006 Polaris 600 Switchback | Owners Manual - Page 63
    warm-up or when the track is free-hanging. Be sure the rear support is stable. WARNING Use of traction products such as studs, ice growsers, the engine, drive train and track. 1. Use an appropriate stand to securely support the rear of the snowmobile at the rear bumper. The track should be
  • 2006 Polaris 600 Switchback | Owners Manual - Page 64
    Fuel OPERATION WARNING Gasoline is highly flammable and explosive under certain conditions. S Always exercise extreme caution whenever handling gasoline. S Always refuel outdoors or in a well-ventilated area. S Always turn off the engine before refueling. S Do not overfill the tank. Do not fill
  • 2006 Polaris 600 Switchback | Owners Manual - Page 65
    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 fuel lower than 87 octane. CAUTION Operating with obstructed fuel systems will result in
  • 2006 Polaris 600 Switchback | Owners Manual - Page 66
    Oil n Low Oil Indicator Light OPERATION The low oil indicator light will alert the operator if the oil level is low. Visually check the oil level in the bottle. Add oil before further operation of the snowmobile. See page 59 for oil recommendations. n Low Oil Level Maintaining the proper oil
  • 2006 Polaris 600 Switchback | Owners Manual - Page 67
    OPERATION n Engine Stop Switch Push down on the engine stop switch (L) to ground out the ignition and stop the engine quickly. Pull the switch up to the ON position to allow restarting. n Throttle Safety Switch L The throttle safety switch is designed to stop the engine whenever all pressure is
  • 2006 Polaris 600 Switchback | Owners Manual - Page 68
    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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 69
    OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 64 for more information about the engine stop switch and throttle safety switch. SYSTEM Ignition Switch Brake Choke Engine Stop Switch Throttle Safety Switch Tether
  • 2006 Polaris 600 Switchback | Owners Manual - Page 70
    OPERATION Emergency Starting If the recoil starter system fails, an emergency start strap is provided in the tool kit. 1. Open the hood. 2. Remove the left side panel. 3. Using the belt removal tool, follow the directions on the air box to relieve belt tension. 4. Starting at one of the tower struts
  • 2006 Polaris 600 Switchback | Owners Manual - Page 71
    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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 72
    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 4″ (10 cm) off the ground. Remove the key and cover
  • 2006 Polaris 600 Switchback | Owners Manual - Page 73
    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 120. The recommended
  • 2006 Polaris 600 Switchback | Owners Manual - Page 74
    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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 75
    MAINTENANCE Item Periodic Maintenance Interval Table See Page P 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 Brakes Brake System Brake fluid Idle RPM Throttle Lever Oil Pump
  • 2006 Polaris 600 Switchback | Owners Manual - Page 76
    Periodic Maintenance Interval Table Item See Page 150 mi. (240 km) 500 mi. (800 km) MAINTENANCE Frequency 1000 mi. (1600 km) 2000 mi. (3200 km) PreSeason CHASSIS Ski Toe Alignment Suspension Mounting Bolts Steering Fasteners Rear Suspension Fasteners Suspension Shock Oil Cooling Fins and Shroud
  • 2006 Polaris 600 Switchback | Owners Manual - Page 77
    MAINTENANCE Lubrication Front Suspension The front suspension and steering components do not require lubrication. Rear Suspension Lubricate the suspension pivot shafts with Polaris Premium All Season Grease at 500 miles (800 km) initially, every 1000 miles (1600 km) after that, and before off-
  • 2006 Polaris 600 Switchback | Owners Manual - Page 78
    Lubrication MAINTENANCE + 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. Throttle Cable Lubricate the throttle cable
  • 2006 Polaris 600 Switchback | Owners Manual - Page 79
    MAINTENANCE Lubrication n Chaincase Oil Check the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 71. 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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 80
    Lubrication MAINTENANCE 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. Install a new sealing washer on the drain plug. NOTE: The sealing surfaces on the drain plug and the
  • 2006 Polaris 600 Switchback | Owners Manual - Page 81
    MAINTENANCE Spark Plugs General Maintenance A new engine can cause temporary spark plug fouling due to the preservative added during the assembly process. Avoid prolonged idle speeds, which cause plug fouling and carbonization. Change the spark plugs every 2000-2500 miles (3200-4000 km). CAUTION
  • 2006 Polaris 600 Switchback | Owners Manual - Page 82
    will be few combustion deposits. The electrodes are not burned or eroded. 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 overheating, caused by use of an improper spark plug or incorrect throttle body
  • 2006 Polaris 600 Switchback | Owners Manual - Page 83
    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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 84
    cool completely. Open the hood and inspect the muffler and pipes for cracks or damage. Check for weak or missing retaining springs or damper/support grommets. WARNING Hot exhaust system parts can cause serious burns. Allow adequate time for the exhaust system to cool. Never perform this procedure
  • 2006 Polaris 600 Switchback | Owners Manual - Page 85
    MAINTENANCE Carburetor General Maintenance 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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 86
    will 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 61. Cleaning Procedure 1. Turn the fuel valve off. See page 28. 2. Place a container or
  • 2006 Polaris 600 Switchback | Owners Manual - Page 87
    MAINTENANCE Coolant General Maintenance The coolant supplied in the system is a 60/40 mixture of ethylene-glycol and distilled water. This mixture provides protection against freezing. Contact your dealer if greater protection is required. Use Premium 60/40 anti-freeze coolant, which is already
  • 2006 Polaris 600 Switchback | Owners Manual - Page 88
    Driving in deep snow will also help cool the engine. See your dealer for service. Add coolant if the level is low. NOTE: Engine performance will be and a fresh mixture of antifreeze and distilled water should be added. This service must be done when the engine is cold. Ask your Polaris dealer to
  • 2006 Polaris 600 Switchback | Owners Manual - Page 89
    MAINTENANCE General Maintenance Bleeding the Cooling System Use of a non-standard pressure cap will not allow the recovery system to function properly. If the pressure cap needs replacement, contact your dealer for the correct part. WARNING Steam and hot liquids will cause serious burns to your
  • 2006 Polaris 600 Switchback | Owners Manual - Page 90
    General 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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 91
    MAINTENANCE General Maintenance n Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 53. Brake pads must be replaced when the brake pad material becomes thinner than the backing plate (approximately 1/16″). A kit is available for replacing brake
  • 2006 Polaris 600 Switchback | Owners Manual - Page 92
    General Maintenance Brake Fluid MAINTENANCE WARNING After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake
  • 2006 Polaris 600 Switchback | Owners Manual - Page 93
    MAINTENANCE General 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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 94
    General Maintenance NOTE: MAINTENANCE Removing Halogen Bulbs 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 alcohol-moistened towel. 1. Remove the plenum
  • 2006 Polaris 600 Switchback | Owners Manual - Page 95
    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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 96
    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 113. For improved drive-away during extremely cold temperatures, remove the belt and warm it to room temperature. Reinstall it before
  • 2006 Polaris 600 Switchback | Owners Manual - Page 97
    MAINTENANCE General Maintenance 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.
  • 2006 Polaris 600 Switchback | Owners Manual - Page 98
    General Maintenance n Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge on the belt (A) and apply downward pressure while measuring at point B. This measurement should be 1 1/4" (3.2 cm). MAINTENANCE A B Drive Belt
  • 2006 Polaris 600 Switchback | Owners Manual - Page 99
    . 1. Emergency Start Strap 2. L-Wrench 3. Spark Plug Wrench/Screwdriver 4. Scissor Stop Wrench 5. Combination Wrench 6. Open End Wrench 1 2 5 4 3 6 Fall Tune-Up For maximum performance, arrange for a fall service tune-up with your Polaris dealer. 96
  • 2006 Polaris 600 Switchback | Owners Manual - Page 100
    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 WARNING Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure, loss of vehicle control and loss
  • 2006 Polaris 600 Switchback | Owners Manual - Page 101
    adjustments should be made only after the track is warmed up and limber. 1. Turn the machine 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 on page 99) ahead of
  • 2006 Polaris 600 Switchback | Owners Manual - Page 102
    Track Maintenance MAINTENANCE Rail Slide Track Tension If the track needs adjustment: 5. Loosen the rear idler shaft bolt (D). 6. Loosen the locknuts (A). 7. Tighten or loosen the track adjusting screws (B) as necessary to provide equal adjustment on both sides of the track. 8. Repeat the
  • 2006 Polaris 600 Switchback | Owners Manual - Page 103
    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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 104
    Steering System MAINTENANCE Steering Inspection and Adjustment Each week, or before a long ride, check all steering system fasteners and tighten if necessary. + + + + 101
  • 2006 Polaris 600 Switchback | Owners Manual - Page 105
    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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 106
    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 6″ (15.2 cm) from the ground. 2. Remove the attaching nuts and pry the skag (+) downward
  • 2006 Polaris 600 Switchback | Owners Manual - Page 107
    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 n n n n n n n n n Check suspension mounting bolts for tightness. Check
  • 2006 Polaris 600 Switchback | Owners Manual - Page 108
    Suspension Maintenance 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 108 for the part numbers of Polaris products. Cleaning and Preservation
  • 2006 Polaris 600 Switchback | Owners Manual - Page 109
    except the driven clutch shaft bushing as outlined in the Master Repair Manual. See your dealer. Engine Protection Proper preparation of the engine and be fogged with fogging oil. Follow the engine fogging instructions provided on the container. Always add Premium Carbon Clean or a fuel conditioner
  • 2006 Polaris 600 Switchback | Owners Manual - Page 110
    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. See illustration. Transporting the Snowmobile Whenever the snowmobile is transported: 1. Turn
  • 2006 Polaris 600 Switchback | Owners Manual - Page 111
    POLARIS PRODUCTS Part No. 2870791 2871098 2871097 2871240 2871721 2871722 2872347 2874438 2874439 2874443 2873105 2872951 2871312 2871322 2871423 2871329 2871323 2871534 2871326 2870652 2870990 2872893 2870505 2872889 2872890 Description Engine Lubricants Fogging Oil (12 oz. Aerosol) Premium 2-
  • 2006 Polaris 600 Switchback | Owners Manual - Page 112
    Engine Troubleshooting TROUBLESHOOTING CAUTION: Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Probable Cause Solution S SEE YOUR DEALER. Erratic engine Drive clutch binding operating RPM during Driven clutch acceleration
  • 2006 Polaris 600 Switchback | Owners Manual - Page 113
    TROUBLESHOOTING Engine Troubleshooting Problem Noise in drive system Probable Cause Broken drive clutch components Bearing failure/ chaincase, jackshaft, or front drive shaft Drive belt surface flat spots Drive chain
  • 2006 Polaris 600 Switchback | Owners Manual - Page 114
    Engine Troubleshooting Problem Engine turns but fails to start TROUBLESHOOTING Probable Cause Faulty ignition Solution S to engine Poor engine compression S Mixture is too lean. This indicates a major engine problem that must be repaired before the engine is run. SEE YOUR DEALER. S Replace
  • 2006 Polaris 600 Switchback | Owners Manual - Page 115
    TROUBLESHOOTING Problem Rear suspension bottoms too easily Suspension Troubleshooting Solution (perform only one change at a time) - Verify sag dimension (see page 42). Adjust torsion spring blocks or install optional torsion springs to achieve correct
  • 2006 Polaris 600 Switchback | Owners Manual - Page 116
    Causes Driving at low RPM Insufficient warm-up TROUBLESHOOTING Belt Wear/Burn Diagnosis Solutions S Drive at higher RPMs. Gear the machine down. Check belt deflection. S Warm the engine at least five minutes. Take the
  • 2006 Polaris 600 Switchback | Owners Manual - Page 117
    information contained in this manual. Your dealer is also familiar with Polaris policies and procedures and will be happy to assist you. When contacting us about parts, service, or warranty, always provide the following information: 1. Serial number 5. Details of trouble experienced 2. Model number
  • 2006 Polaris 600 Switchback | Owners Manual - Page 118
    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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 119
    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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 120
    dealer to perform the required vehicle PreDelivery Inspection, perform all applicable service bulletins and have the consumer sign the PDI form prior to products for lubrication and maintenance as directed by the Owner's manual is highly recommended. Should a failure occur during the warranty
  • 2006 Polaris 600 Switchback | Owners Manual - Page 121
    oil. S Piston seizures, unless caused by a defective engine component. S Failures caused due to improper adjustments. S Failure due to unauthorized service. S 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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 122
    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
  • 2006 Polaris 600 Switchback | Owners Manual - Page 123
    MAINTENANCE 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)
  • 2006 Polaris 600 Switchback | Owners Manual - Page 124
    MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 121
  • 2006 Polaris 600 Switchback | Owners Manual - Page 125
    Surfaces ...Driving Responsibly ...95 94 93 113 87 13 75 15 16 15 19 B Bearings ...106 Before Starting the Engine ...51-55 Belt Troubleshooting ...113 Bleeding the Cooling System ...86 Bleeding the Hydraulic Brake System 90 Brake Components ...88 Brake Fluid ...89 Brake Lever Travel ...53 Brake
  • 2006 Polaris 600 Switchback | Owners Manual - Page 126
    Lubrication ...74-77 S SAFETY ...8-24 Safety Decals and Locations ...21-24 Sag ...42 Seat Storage Compartment ...28 Second Year Engine Service Contract 118 Service And Warranty Information . 114 Shock Valving ...40 Shock, Rapid Adjust, ARVIN ...45 Shock, Rear, Indy Select ...44 Shocks, Rear ...44
  • 2006 Polaris 600 Switchback | Owners Manual - Page 127
    , Front, IQ 39-40 Suspension Adjustments, Rear ...41-45 Suspension Maintenance ...104-105 Suspension Performance Tips ...41 Suspension Troubleshooting ...112 Symbols ...8 V Vehicle Identification Numbers ...7 W Warning Labels ...21-24 WARRANTY ...114-119 Wear Strips ...49 WELCOME ...1 Windchill
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