Snowmobile Polaris 600 IQ Racer (2015 year). Manual - part 19

79

MAINTENANCE

Lights

Headlight Bulb Installation

1. Hold the bulb by its metal base and install it into the wire harness.

2. Insert the bulb into the housing.

3. Connect the spring to the housing.

4. Carefully flip the spring back into the housing, placing it around the 

wire harness.

5. Reinstall the plenum covering on the headlight assembly.

6. Verify headlight aim.

Taillight/Brake Light Replacement

1. Remove the screws securing the taillight lens. Remove the lens.

2. Push the bulb inward and turn it counterclockwise to remove it.

3. Install a new bulb. Push the bulb inward and turn it clockwise to 

secure it.

4. Reinstall the taillight lens.

80

MAINTENANCE

Clutch System

Periodically inspect clutch sheaves for damage, wear or belt residue. To 
maintain optimum performance, clean with non-oil based cleaners such 
as isopropyl alcohol. 

WARNING! If you become aware of higher than normal clutch engagement or 
an unusual vibration or shift pattern, see your dealer immediately. Do not 
operate the machine until repairs have been made. 

All clutch maintenance and repairs must be performed by an authorized 
POLARIS dealer. Any unauthorized modifications to clutches, such as 
adding or removing weights, will void the warranty.

NOTICE: The bushings in the weights and rollers of POLARIS clutches are 

made of a material that may be damaged if lubricated. Do not 
lubricate clutch bushings.

Clutch Alignment Offset

Clutch 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.

81

MAINTENANCE

Clutch System

Drive Belt Condition

Periodically check the condition and tension of the drive belt, and 
always carry a spare. Inspect the belt for signs of 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 
106.

Always carry a spare drive belt for emergency use. Store the spare belt 
on top of the electrical box, which is mounted to the clutch cover.

For improved drive-away during extremely cold temperatures, remove 
the belt and warm it to room temperature. Reinstall it before starting the 
snowmobile.

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 1/4 
inches (3.2 cm).

Drive Belt Adjustment

1. Install the L-wrench into the open threaded hole in the outer sheave 

of the clutch (see page 82). Turn the wrench clockwise slightly to 
remove pressure from the sheaves.

2. Loosen the 7/16-inch jam nut on the belt width adjuster.

3. Using a 1/8-inch Allen wrench, turn the set screw inward 

(clockwise) to increase the distance between the sheaves or outward 
(counterclockwise) to decrease the distance.

4. Tighten the jam nut. Remove the L-wrench and store it in the tool 

kit.

1

2

82

MAINTENANCE

Clutch System

Drive Belt Removal 

NOTICE: Do not attempt to remove the drive belt after operating in reverse (if 

equipped). The snowmobile must be stopped after forward motion to 
prevent damage to components during belt removal. Rotate the driven 
clutch counterclockwise 1/4 turn by hand to ensure forward 
engagement before attempting to remove the belt.

1. Stop the engine after 

operating in a forward 
motion. Wait for the engine 
to come to a complete stop.

2. Apply the brake (or lock the 

parking brake, if equipped).

3. Open the hood and remove 

the left side panel. Remove 
the clutch guard retaining 
pin and open the clutch 
guard.

4. Rotate the driven clutch counterclockwise 1/4 turn by hand to 

ensure forward engagement.

5. Locate the L-wrench in the tool kit. Install the wrench into the open 

threaded hole in the outer sheave of the clutch (X).

6. Turn the wrench clockwise until the sheaves open far enough to 

remove the belt. If the wrench does not turn readily, rotate the 
driven clutch counterclockwise an additional 1/4 turn by hand and 
try again.

7. Grasp the belt at the lower edge and remove it.

X