1985 POLARIS 600 Snowmobile Service Repair Manual

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Type: Snowmobile

Vendor:

Sku: 92765

Tags: 1985 600 ATV Misc Polaris Powersports Snowmobile

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Description

The 1985 Polaris 600 is a snowmobile renowned for its robust engineering and reliable performance, characteristic of Polaris's legacy in powersports. Designed for enthusiasts seeking adventure on snow-covered terrains, this model offers a balanced combination of power and agility. Its two-stroke, twin-cylinder engine, approximately 590-600cc, delivers an estimated 70-85 horsepower, providing ample capability for various riding conditions. The vehicle features a Continuously Variable Transmission (CVT) for smooth power delivery and is equipped with essential safety features like an engine kill switch and tether. This comprehensive service manual provides detailed information for the maintenance, repair, and troubleshooting of your 1985 Polaris 600 snowmobile. It covers critical systems including the engine, drivetrain, suspension, braking, electrical, and fuel systems. Within its approximately 300-400 pages, you will find step-by-step procedures for routine maintenance, engine rebuilds, clutch service, and electrical diagnostics. The manual also includes essential technical specifications, wiring diagrams, and diagnostic flowcharts, making it an indispensable resource for Polaris dealership technicians, certified repair shops, and experienced snowmobile owners aiming to ensure optimal performance and longevity.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Year:

Vehicle Type:

Snowmobile

Codes

Product Name:

1985 POLARIS 600 Snowmobile Service Repair Manual

👋 Introduction

Market Position

Target Audience:

Polaris dealership technicians, certified repair shops, and experienced snowmobile enthusiasts.

Competitive Analysis

Manual Value Proposition:

Provides authoritative, manufacturer-sourced information essential for maintaining and repairing the 1985 Polaris 600 snowmobile, ensuring optimal performance and longevity.

Key Features

Original Manufacturer Content:

Authored by Polaris, ensuring accuracy and completeness as used by their authorized service centers.

Comprehensive Diagrams:

Includes detailed exploded views, wiring diagrams, and component illustrations crucial for identification and assembly.

Diagnostic Tools:

Equipped with diagnostic procedures to efficiently identify and resolve mechanical and electrical issues.

📋 Manual Details

Coverage Areas

Primary Coverage:

Maintenance, Repair, Troubleshooting, Overhaul, Diagnostics

Page Count

Estimated Page Count:

300-400

Manual Type

Manual Type:

Factory Service Manual / Repair Manual

Language

Language:

English

Format

Format:

Print (Likely bound pages)

📖 Manual Coverage

Systems Covered

Engine System:

Detailed disassembly, assembly, inspection, and repair procedures for the Polaris 600cc engine, including carburetor tuning, ignition system diagnostics, cooling system maintenance, and exhaust system service.

Drivetrain System:

Comprehensive coverage of the CVT (Continuously Variable Transmission) system, including clutch inspection, belt replacement, roller and spring service, and gearbox maintenance.

Suspension System:

Information on front and rear suspension components, including shock absorber servicing, ski alignment, track tension adjustment, and slider rail inspection.

Braking System:

Procedures for brake system maintenance, including pad replacement, caliper servicing, and hydraulic fluid checks and bleeding (if applicable).

Electrical System:

Detailed wiring diagrams, troubleshooting guides for ignition, lighting, and starter systems, and component testing procedures.

Fuel System:

Carburetor identification, adjustment, and rebuild procedures, fuel pump operation (if applicable), and fuel line inspection and replacement.

Chassis And Body:

Body panel removal and installation, seat repair, handlebar and control assembly maintenance, and general chassis inspection.

Procedures Included

Routine Maintenance:

Oil changes, spark plug replacement, air filter cleaning/replacement, track adjustment, lubrication points.

Troubleshooting Guides:

Systematic diagnostic flowcharts for common performance issues, starting problems, and component failures.

Engine Rebuild:

Step-by-step instructions for complete engine disassembly, component inspection, measurement of critical tolerances, piston and ring replacement, crankshaft and connecting rod service, and cylinder head overhaul.

Clutch Service:

Primary and secondary clutch maintenance, including roller inspection, spring replacement, weight adjustment, and belt alignment procedures.

Electrical Diagnostics:

Testing of ignition coils, stators, flywheels, and starter motors; troubleshooting of lighting and accessory circuits.

Suspension Adjustment:

Track tension settings, ski stance adjustments, and shock absorber pre-load settings.

Carburetor Adjustment:

Idle speed, mixture screw settings, and jetting information for optimal performance and fuel efficiency.

Technical Depth

Diagnostic Level:

Advanced diagnostic procedures, including multimeter usage, circuit testing, and interpretation of engine performance data.

Repair Scope:

Complete repair and overhaul capabilities, suitable for both dealership technicians and experienced DIY mechanics.

Specifications Detail:

Includes critical torque specifications, clearance measurements, and material specifications for engine and drivetrain components.

📊 Manual Specifications

File Format

Digital Format Availability:

N/A (Assumed to be original print)

Print Quality

Print Quality Assessment:

High (Factory published manuals are typically well-printed with clear diagrams).

Binding Type

Binding Type:

Likely bound (e.g., spiral, perfect binding, stapled pages)

Paper Type

Paper Type:

Durable, often glossy paper suitable for workshop environments.

⚙️ Engine Specifications

Primary Engine

Engine Type:

Two-stroke, Twin-cylinder

Displacement:

Approximately 590-600cc (Specific designation is '600')

Performance

Horsepower:

Estimated 70-85 HP (Varies by specific model tuning and year).

Torque:

Manufacturer-specific data required for precise torque figures.

Fuel System

Carburetion:

Likely dual Mikuni VM or similar side-draft carburetors (Specific model number required for exact carb type).

Fuel Type:

Unleaded gasoline, mixed with 2-stroke oil (typically 40:1 or 50:1 ratio, specified in manual).

Ignition System

Ignition Type:

CDI (Capacitor Discharge Ignition)

🔧 Transmission

Standard

Transmission Type:

Automatic Continuously Variable Transmission (CVT)

Optional

Optional Transmission:

N/A (CVT was standard for this era/model type)

Features

Clutch System:

Primary drive clutch and secondary driven clutch (often referred to as Comet or Polaris-branded clutches).

Drive System:

Chain drive to drive axle, or direct drive depending on chassis configuration.

📐 Dimensions

Exterior

Length:

Manufacturer specific, typically 90-110 inches.

Width:

Manufacturer specific, typically 35-45 inches.

Weights

Dry Weight:

Manufacturer specific, likely in the range of 350-450 lbs.

🛡️ Safety Features

Ratings

Safety Features Design:

Focus on rider control, engine shut-off tether, and secure seating.

Active Features

Throttle Control:

Thumb throttle for variable speed control.

Braking Control:

Handlebar-mounted brake lever.

Passive Features

Engine Kill Switch:

Standard safety feature.

Engine Tether:

Standard kill switch tether for rider safety.

💡 Technology Features

Infotainment

Infotainment System:

N/A (Basic instrumentation: speedometer, tachometer, odometer).

Driver Assistance

Driver Assistance Features:

Connectivity

Connectivity Options:

🔧 Maintenance

Service Intervals

Oil Change Interval:

As per manual; typically every 50-100 operating hours or annually.

Spark Plug Replacement:

As per manual; typically every 1,000-2,000 miles or as needed based on condition.

Clutch Inspection:

Regular inspection before each season and after significant use, with detailed interval specified in manual.

Fluid Specifications

2 Stroke Oil Type:

API-TC or JASO FD certified synthetic or semi-synthetic 2-stroke snowmobile oil (Specific brand/grade in manual).

Gear Lube Type:

Specific gear oil viscosity and type (e.g., SAE 80W-90) as detailed in the manual.

Known Issues

Carburetor Fouling:

Common issue with older 2-stroke engines, often due to improper fuel mix or stale fuel. Manual covers cleaning and adjustment.

Clutch Wear:

Wear on clutch rollers, springs, and buttons is common. Manual details inspection and replacement procedures.

Track Tension:

Track can stretch over time, requiring adjustment. Manual outlines correct tensioning procedures.

Engine Seals:

Crankshaft seals can deteriorate, leading to air leaks and performance issues. Manual details seal replacement.

📚 Vehicle History

Brand Heritage

Polarisfamily:

Polaris is a long-standing American manufacturer of powersports vehicles, with a significant history in snowmobiles dating back to the 1950s.

Model Evolution

1985 Era Polarissnowmobiles:

The mid-1980s marked a period of performance and technology advancement for Polaris, with models like the '600' often representing a balance of power and versatility in their lineup.

Production

Manufacturing Location:

Polaris vehicles are primarily manufactured in the United States.

🏆 Awards & Recognition

Recognitions

1985 Era Industry Awards:

While specific awards for the 1985 Polaris 600 are not widely documented, Polaris consistently received recognition for its innovation and performance in snowmobiling during this era.

Ratings

Owner Satisfaction:

Subjective, but generally Polaris snowmobiles of this period were well-regarded for their reliability and performance within the enthusiast community.