Snowmobile Polaris 600 IQ Racer (2015 year). Instruction - part 18

75

MAINTENANCE

Brakes

Brake Fluid

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 fluid to drop, which can lead to early brake fade and the possibility of 
accident or serious injury. 

Keep the master cylinder cover free of dirt and debris. The vent slits allow for 
diaphragm movement, and if they become plugged, movement of brake fluid 
below the diaphragm may be restricted, altering brake function.

View the brake fluid level through the sight glass on the top of the 
master cylinder. The eye will appear dark when the fluid level is full. If 
the sight glass is any color other than black, add brake fluid. 

Maintain the brake fluid level between the MIN and MAX marks on the 
master cylinder reservoir. Use only POLARIS DOT 4 high temperature 
brake fluid. See page 100 for the part numbers of POLARIS products.

Replace brake fluid at least every two years.

NOTICE: Brake fluid will damage labels, paint and some plastics. Always wipe 

up spills immediately.

WARNING

76

MAINTENANCE

Brakes

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 lead to serious injury or death. 
Never operate the vehicle with a spongy-feeling brake lever.

During the bleeding procedure, keep the brake handle as level as 
possible. The reservoir must be in this position to minimize the 
possibility of air entering the system through the reservoir vent.

1. Remove the brake master cylinder reservoir cover and gasket.

2. Fill the master cylinder reservoir to between the MIN and MAX 

marks or 1/4-5/16 inch (.6-.8 cm) below the lip of the reservoir 
opening. Reinstall the gasket and cover.

3. Slip a rubber tube over the ball of the bleeder valve and direct the 

flow of fluid into an approved container.

4. Squeeze the brake lever a full stroke. Then unscrew the bleeder 

valve 3/4 of a turn to release air.

5. Close the bleeder valve and release the brake lever.

6. Repeat steps 4 and 5 until fluid flows from the bleeder valve in a 

solid stream free of air bubbles.

WARNING! Overfilling the master cylinder leaves no room for fluid expansion 
and may cause the brakes to lock, resulting in serious injury or death. Always 
add brake fluid to the fill line as recommended.

7. After bleeding is complete, refill the reservoir to the proper level. 

See page 75. 

8. Reinstall the gasket and cover.

77

MAINTENANCE

Lights

Headlight Adjustment

The headlight may be adjusted for vertical aim using the following 
procedure.

1. Place the snowmobile on a level surface with the headlight 

approximately 25 feet (7.6 m) from a wall.

2. Measure the distance from the floor to the center of the headlight 

and make a mark on the wall.

3. Start the engine and turn the headlight switch to high beam.

4. Observe the headlight aim. The most intense part of the headlight 

beam should be aimed 2 inches (5.1 cm) below the mark placed on 
the wall.

TIP: Rider weight must be included on the seat.

5. Turn the adjustment nut, located inside the hood, just below the 

headlamp opening. Turn the knob in or out as needed for proper 
aim.

2

”

 (5.1 cm)

Lamp Center Height

25 ft. (7.6 m)

Adjustment Nut

78

MAINTENANCE

Lights

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.

Headlight Bulb Removal

1. Remove the plenum covering 

from the headlight assembly.

2. Pinch the ends of the spring (1) 

together and lift until it 
releases from the spring 
retainer.

3. Lift spring carefully around 

wire harness (2) and flip to 
outside of housing.

4. With the wire harness attached to the bulb (3), withdraw bulb from 

housing.

5. Grasp bulb by metal base and carefully separate bulb from harness.

1

2

3