Snowmobile Polaris 600 IQ LXT (2015 year). Manual - part 25

103

MAINTENANCE

Lights

Removing Halogen Bulbs

Tip: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a resi-

due, 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 

covering from the 
headlight assembly.

2. Lift the rubber boot to 

expose the bulb.

3. Push down on the spring to 

release it from the housing.

4. With the wire harness 

attached to the bulb, with-
draw the bulb from the 
housing.

5. Grasp the bulb by its metal base and carefully separate the bulb 

from the harness.

Installing Halogen Bulbs

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. Adjust headlight aim. See page 31.

Replacing Taillight Bulbs

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

2. Push the bulb inward and turn it counter-clockwise to remove it.

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

secure it.

4. Reinstall the taillight lens.

Spring

Harness

Bulb

104

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 snowmobile until repairs have been made. 

WARNING! 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.

105

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 
127.

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 on the belt 
and apply downward pressure 
while measuring at point A. This 
measurement should be 1 1/4" 
(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 106). Turn the wrench clockwise slightly to 
remove pressure from the sheaves.

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

3. Using a 1/8" Allen wrench, adjust the threaded set screw as needed.

Tip: Turn the set screw in (clockwise) to increase the distance between the 

sheaves and out (counter-clockwise) to decrease the distance.

4. Tighten the jam nut.

Straight 

Edge

Measure

A

106

MAINTENANCE

Clutch System

Drive Belt Removal

NOTICE: Do not attempt to remove the drive belt after operating in reverse. The 

snowmobile must be stopped after forward motion to prevent damage 
to components during belt removal.

1. Stop the engine after operat-

ing in a forward motion.

2. Turn the ignition key off. 

Wait for the engine to come 
to a complete stop.

3. Lock the parking brake.

4. Open the hood.

5. Remove the left side panel.

6. Rotate the driven clutch 

counter-clockwise 1/4 turn 
by hand to ensure forward 
engagement before attempting to remove the belt.

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

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

8. 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 counter-clockwise an additional 1/4 turn by hand and 
try again.

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

X