PMS 419
IMPORTANT NOTICE TO OWNER
Modifications to this snowmobile are not recommended
and may result in voided warranty coverage.
Please read the warranty section of this manual carefully.
600 RMK
600 PRO RMK
800 RMK
800 PRO RMK
800 RMK ASSAULT
Snowmobile Owner's Manual
for Maintenance and Safety
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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.
WARNING
The engine exhaust from this product contains chemicals known to the State
of California to cause cancer, birth defects or other reproductive harm.
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WELCOME
Thank you for purchasing a POLARIS vehicle, and welcome to our
world-wide family of POLARIS enthusiasts. Be sure to visit us online at
www.polaris.com for the latest news, new product introductions,
upcoming events, career opportunities and more.
Here at POLARIS we proudly produce an exciting line of utility and
recreational products.
• Snowmobiles
• All-terrain vehicles (ATVs)
• Low emission vehicles (LEVs)
• RANGER® utility vehicles
• RZR® sport vehicles
• VICTORY® motorcycles
• GEM® vehicles
We believe POLARIS sets a standard of excellence for all utility and
recreational vehicles manufactured in the world today. Many years of
experience have gone into the engineering, design, and development of
your POLARIS vehicle, making it the finest machine we’ve ever
produced.
For safe and enjoyable 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 Service Dealer® (MSD)
technician.
Your POLARIS dealer knows your vehicle best and is interested in your
total satisfaction. Be sure to return to your dealership for all of your
service needs during, and after, the warranty period.
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The following are registered trademarks of POLARIS Industries Inc.:
POLARIS®
PERC®
RMK®
ASSAULT®
QUICKDRIVE™ is a trademark of POLARIS Industries Inc.
Copyright 2013 POLARIS Sales Inc. All information contained within this publication
is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor
discrepancies may result between the actual vehicle and the information presented in
this publication. Depictions and/or procedures in this publication are intended for
reference use only. No liability can be accepted for omissions or inaccuracies. Any
reprinting or reuse of the depictions and/or procedures contained within, whether whole
or in part, is expressly prohibited.
The original instructions for this vehicle are in English. Other languages are provided as
translations of the original instructions.
Printed in U.S.A.
600 RMK / 600 PRO RMK / 800 RMK / 800 PRO RMK / 800 RMK ASSAULT
2014 Owner's Manual P/N 9924268
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TABLE OF CONTENTS
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
This section contains helpful information for owners and drivers and
illustrates the location of important identification numbers that should
be recorded in the owner's manual.
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
This section describes safe vehicle operation and identifies warning
labels and their locations.
Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
This section identifies the locations of your snowmobile's controls and
features.
The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . 50
This section includes suspension set-up information and explains how to
make additional suspension adjustments for the perfect riding
experience.
Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . 56
This section explains procedures that must be performed before riding.
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
This section explains proper engine break-in, operation of features and
general operating procedures.
Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 78
This section defines your role, and your dealer's role, in your
snowmobile's regular maintenance.
Specifications. . . . . . . . . . . . . . . . . . . . . . . . . 118
POLARIS Products. . . . . . . . . . . . . . . . . . . . . 122
Troubleshooting. . . . . . . . . . . . . . . . . . . . . . . 123
Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 127
Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 135
Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 137
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INTRODUCTION
Important Notes for Owners and Drivers
After reading this manual, store it in the snowmobile for convenient
reference. It should remain with the snowmobile when the snowmobile
is 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 at specific mileage intervals.
You and your dealer must complete the registration form included with
your snowmobile and forward it to us. This completed form is necessary
to ensure warranty coverage.
Protect and preserve your right to ride by joining your local trail riding
clubs.
When teaching inexperienced operators to ride, set up a predetermined
course for practice. Make sure they know how to drive and control the
snowmobile before allowing them to make longer trips. Teach them
proper snowmobile courtesy, and enroll them in driver’s training and
safety courses sponsored by local or state organizations.
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INTRODUCTION
Preservation of the Environment
POLARIS is committed to supporting an environmental education
campaign. We encourage state and provincial governments across the
snowbelt to adopt rigorous safety training programs that encourage
protection 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 most publicized issues about snowmobiles is noise. The
Society of Automotive Engineers (SAE), the standard-setting body for
snowmobile development, recommends that snowmobiles conform to
prescribed sound levels.
POLARIS snowmobiles are engineered to conform to these SAE
standards. Our muffler systems are designed to reduce noise levels and
must not be altered or removed. The sound of your snowmobile may not
be welcome to non-snowmobilers, so you have a responsibility to
operate your snowmobile with concern for others. We do our part by
manufacturing quieter machines; we ask your help to further reduce the
impact of noise by operating your snowmobile safely and responsibly.
Air Pollution
POLARIS engineers continuously investigate ways to reduce emission
levels of two-stroke engines. We expect our efforts to lead to the
reduction of potential air pollution.
In addition to our technological research, we encourage government
agencies, manufacturers, distributors, dealers, ecologists, and other
interested parties to work together to develop data on environmental
topics.
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INTRODUCTION
Vehicle Identification Numbers
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 lost, the ignition switch
must be replaced.
Tunnel VIN
Vehicle Model Number: ___________________________________________________
Tunnel VIN (right side of tunnel): ____________________________________________
Engine Serial Number (on recoil housing): _____________________________________
Key Number: ____________________________________________________________
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SAFETY
Operator Safety
The following signal words and symbols appear throughout this manual
and on your vehicle. Your safety is involved when these words and
symbols are used. Become familiar with their meanings before reading
the manual.
The safety alert symbol indicates a potential personal injury hazard.
DANGER
A DANGER indicates a hazardous situation that, if not avoided, will result in
death or serious injury.
WARNING
A WARNING indicates a hazardous situation that, if not avoided, could result in
death or serious injury.
CAUTION
A CAUTION indicates a hazardous situation that, if not avoided, could result in
minor or moderate injury.
NOTICE
A NOTICE indicates a situation that could result in property damage.
The Prohibition Safety Sign indicates an action NOT to take in order
to avoid a hazard.
The Mandatory Action Sign indicates an action that NEEDS to be
taken to avoid a hazard.
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SAFETY
Operator Safety
Follow the recommended maintenance program beginning on page 79
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 attention. DO NOT drink alcohol or use
drugs or medications before or while driving or riding as a passenger. They will
reduce your alertness and slow your reaction time.
Snowmobiles are capable of traveling at high speeds. Use extra caution to
ensure operator safety. Make sure your snowmobile is in excellent operating
condition at all times. Always check major and vital safety components before
every ride.
All POLARIS snowmobiles are designed and tested to provide safe operation
when used as directed. Failure of critical machine components may result from
operation with any modifications, especially those that increase speed or power.
DO NOT MODIFY YOUR MACHINE. The snowmobile may become
aerodynamically unstable at speeds higher than those for which it is designed.
Loss of control may occur at higher speeds. Modifications may also create a
safety hazard and lead to bodily injury.
The warranty on your entire machine is terminated if any equipment has been
added, or any modifications have been made, to increase the speed or power of
the snowmobile.
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SAFETY
Operator Safety
Stay Clear of Track
Your snowmobile is propelled by a revolving track that must be partially
exposed for proper operation. Do not stand on the plastic flap.
WARNING! Serious injuries may result if
hands, feet, or clothing become entangled
NO STEP
in the track. Be alert when riding, and
remain properly seated to stay clear of the
track. Never hold the snowmobile up or
stand behind it 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, open the side panels or hood, make the adjustment, secure
shields and guards, secure the side panels and hood, and then restart the
engine to check its operation.
WARNING! Serious injury can occur if fingers or clothing contact the moving
parts of an engine. Always stop the engine before attempting adjustments.
Riding Position
Operating a snowmobile requires skill and balance for proper control.
Rider positions may vary with experience and the features available on
some snowmobiles, but under many conditions, the proper position is to
be seated with both feet on the running boards and both hands on the
handlebar grips for proper throttle, brake and steering control.
WARNING! Improper riding position may reduce control and could result in
serious injury or death. Always ride in a position that allows for control of your
vehicle.
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SAFETY
Operator Safety
Riding Apparel
Helmet
Wearing a helmet can prevent a severe head injury. Whenever riding a
POLARIS vehicle, always wear a helmet that meets or exceeds
established safety standards.
Approved helmets in the USA and Canada bear a U.S. Department of
Transportation (DOT) label.
Approved helmets in Europe, Asia and Oceania
bear the ECE 22.05 label. The ECE mark consists
4
E
of a circle surrounding the letter E, followed by the
distinguishing number of the country which has
granted approval. The approval number and serial
number will also be displayed on the label.
051039
0006.31
Eye Protection
Do not depend on eyeglasses or sunglasses for eye protection.
Whenever riding a POLARIS vehicle, always wear shatterproof goggles
or use a shatterproof helmet face shield. POLARIS recommends
wearing approved Personal Protective Equipment (PPE) bearing
markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye
wear is kept clean.
Clothing
Be prepared, be warm and be
comfortable when riding. Be aware
of the weather forecast, especially
the windchill, and dress
accordingly. See the chart on page
20.
WARNING! Avoid wearing loose
clothing or long scarves, which can
become entangled in moving parts and
cause serious injury. Always wear an
approved helmet and eye protection.
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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.
Survival Preparation
For your safety, always ride in a group of other snowmobilers. Always
tell someone where you're going and how long you expect to be gone. If
it isn't possible to ride with others, and you must travel into remote
areas, always carry survival equipment that's appropriate to the
conditions you may encounter. Such equipment may include, but is not
limited to: extra clothing, a sleeping bag, a flashlight, food and water, a
signaling mirror, a means of building a fire, and a two-way radio or
cellular telephone.
Always carry the owner’s manual on your snowmobile. For added
protection, purchase and carry the following items on your snowmobile
as well:
• Spare Drive Belt
• Extra Set of Spark Plugs
• Tow Rope
• Winter Survival Kit
• Trail Map
• First Aid Kit
• Tool Kit
• Extra Oil
• Fuel Deicer
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SAFETY
Operator Safety
Rider Capacity
This snowmobile is designed for a single rider only. Never carry a
passenger on this snowmobile.
Excessive Speed
WARNING! High speed driving, especially at night, could result in serious injury
or death. Always reduce speed when driving at night or in inclement weather.
Always observe all state and local laws governing snowmobile
operation and speed limits. Always be alert and pay attention to the trail
ahead. If your speed is 40 MPH (64 km/h), your snowmobile is traveling
about 60 feet (18 m) per second. If you look back for only two seconds,
your snowmobile will travel about 120 feet (36 m). If your speed is 60
MPH (96 km/h), your snowmobile will travel about 180 feet (55 m) in
two seconds.
Traveling at night requires extra caution. Check headlight and taillight
to ensure proper operation, and don’t over-drive your headlight beam.
Always be able to bring your snowmobile to a stop in the distance
illuminated by the headlight.
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SAFETY
Operator Safety
Driver Awareness
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 wires on utility poles
are also difficult to distinguish.
Make sure the way is clear before crossing
railroads and other roads and highways.
The noise of your snowmobile will drown
out the sound of approaching vehicles.
Look ahead, behind, and to both sides
before turning or crossing railroad tracks
or highways. Steep embankments may
also hide your view. Always leave yourself
a way out.
R R
Variances in snow depth and/or water currents may result in uneven ice
thickness. You may drown if you break through the ice. Never travel on
frozen bodies of water unless you have first verified that the ice is
sufficiently thick to support the weight and moving force of the
snowmobile, you and your cargo, together with any other vehicles in
your party. Always check with local authorities and residents to confirm
ice conditions and thickness over your entire route. Snowmobile
operators assume all risk associated with ice conditions on frozen bodies
of water.
When teaching inexperienced operators to ride, set up a predetermined
course for practice. Make sure they know how to drive and control the
snowmobile before allowing them to make longer trips. Teach them
proper snowmobile courtesy, and enroll them in driver's training and
safety courses.
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SAFETY
Operator Safety
Avalanches
Snowmobilers should always be properly
trained and equipped before traveling in
mountainous terrain:
• Take an avalanche class
• Travel with experienced people
• Travel on designated trails
• Make sure each person is equipped
with a shovel, probe and avalanche
beacon.
You don't have to be snowmobiling on a slope for an avalanche to occur.
Be aware that all of the snow is connected. You may be riding on a flat
slope or snow covered road, but if the snowpack above is unstable
enough you can trigger an avalanche on a steeper slope above you.
Always be aware of snow conditions above you as you travel in
mountainous terrain.
Before riding in mountainous terrain, call or log on to your local
avalanche advisory to get current weather and snow stability
information.
For more information about avalanche training and avalanche
conditions, contact local law enforcement in your area, or visit the
American and Canadian online avalanche centers at
www.avalanche.org.
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SAFETY
Operator Safety
Ice and Snow Build-up
WARNING! Ice and snow build-up may interfere with the steering of your
snowmobile, 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
is encountered, remove ice and snow build-up that may be obstructing
the steering linkage.
Driving on Slippery Surfaces
WARNING! Never attempt an abrupt change of direction when operating on
slippery surfaces. Proceed slowly and use extra caution. Driving on ice or hard-
packed snow reduces steering and braking control, which may result in loss of
control and serious injury or death. Slow down and use extra caution when
operating on slippery surfaces.
Inadequate Snow Conditions
Since snow provides the only lubrication for the power slide suspension
and, on liquid cooled models, cooling for the engine, adequate snow
cover is a requirement for operation of your snowmobile.
NOTICE: Driving in too little snow will result in excessive wear and damage to
the slide rail, track and/or engine.
WARNING! Inadequate cooling and lubrication will lead to overheating of the
slide rail and track, causing premature wear, damage and failure, which can
result in serious injury. Reduce speeds and frequently drive into fresh snow to
allow adequate cooling and polishing of the slide rail and track surfaces. Avoid
operating for prolonged periods on ice, hard-packed surfaces or roads.
Operating in Deep Snow
If the snowmobile becomes stuck in snow, clear the running board area
of snow, then step down the snow in front of the snowmobile so that
when the throttle is opened, the snowmobile will be able to climb up and
over the snow.
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SAFETY
Operator Safety
Driving Downhill
When riding downhill, shift your weight to the rear of the snowmobile
and reduce your speed to a minimum. Apply just enough throttle to keep
the clutch engaged, allowing the engine's compression to help slow the
snowmobile and keep it from rolling freely downhill.
WARNING! When driving on long downhill stretches, pump the brakes. Riding
the brakes may cause the brake system to overheat, which may result in brake
failure. Excessive or repetitive use of the brakes for high speed stops will also
cause an overheated brake system. This condition may lead to a sudden loss of
brakes and/or fire and may result in serious injury or death.
Driving in Hilly Terrain
WARNING! Climbing a hill or crossing the face of a slope may result in loss of
balance and snowmobile rollover, causing serious injury or death. Use caution
and good judgement when driving in hilly terrain.
Use extra caution when operating in hilly terrain. If climbing a hill is
unavoidable, keep your weight low and forward. If you must cross the
face of a slope, keep your weight on the uphill side of the snowmobile to
maintain proper balance and avoid possible roll-over.
Slow down when reaching the crest of a hill. Be prepared to react to
obstacles, sharp drops or other people or vehicles that may be on the
other side of the hill.
If you're unable to continue up a hill, turn the snowmobile downhill
before it loses momentum. If this isn't possible, spin the track just
enough to dig in to prevent it from rolling back down the hill. Stop the
engine and set the parking brake (if equipped). Keeping away from the
downhill side of the snowmobile, pull the rear of the snowmobile
around and point the front end and skis downhill. Remount the
snowmobile, restart the engine, release the parking brake, and descend
the hill carefully.
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SAFETY
Operator Safety
Drive Belt
Do not operate the engine with the drive belt removed.
Any servicing that requires operation without a belt must be performed
by your dealer.
NOTICE: Operation of the engine with the belt removed may result in injury or
damage to the engine.
Intake Silencer
Do not operate the engine with the intake silencer or filter removed.
NOTICE: 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 before installation. Any tampering may disrupt
this precision balancing and create an unstable condition.
Cold Weather Drive-Away
Whenever your snowmobile has been parked for a length of time,
especially overnight, always make sure the skis and track are loosened
from ice and snow before attempting to drive. Apply the throttle with
enough authority to put the snowmobile into motion, but always operate
within safety limits.
Maneuverability
While much control and maneuverability is achieved through the
steering system and skis, maximum control is achieved by the shifting
of your body weight. Maneuverability will change for lighter operators
or snowmobiles designed to carry a load.
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SAFETY
Operator 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 snowmobile
and with what it will and won't do under various conditions. Even
seasoned drivers should spend some time getting the feel for a
snowmobile before attempting ambitious maneuvers.
• A snowmobile depends on the rider's body position for proper
balance in executing turns, traversing hills, etc. Always start on a
smooth, level area to begin building your operating experience.
• Before allowing someone else to use your snowmobile, know the
extent of their operating skills. Check to see if they've taken a
snowmobile safety course and have an operator's certificate. For their
protection, as well as yours, make sure they take a snowmobile safety
course. Everyone can benefit from the course.
• Don't “jump” your snowmobile over large drifts or similar terrain.
Jumping may injure your back because of spinal compression that
could occur when the snowmobile impacts the ground. The seat and
suspension of your snowmobile have been designed to provide
protection under normal riding conditions. Your snowmobile is not
intended for this kind of use.
• Be courteous to oncoming traffic by dimming your headlights and
reducing your speed.
• When traveling in a group of snowmobiles, don't tailgate (follow too
closely). Leave enough distance between snowmobiles to provide
ample stopping room and to provide protection from flying snow and
debris. Allow even more distance when driving on slippery surfaces
or when driving in darkness or other low visibility conditions. Be
aware of any snowmobile traffic around your vehicle. Drive
defensively to avoid accidents.
• Remove the key from the ignition when you leave the snowmobile
unattended.
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SAFETY
Operator Safety
Windchill/Temperature Charts
The following information is provided to help you determine when
temperatures become dangerous for riding.
WINDCHILL CHART (°F)
Wind
Speed
in
Actual Thermometer Reading (°F)
-5 -10 -15 -20 -25 -30 -35 -40 -45
Equivalent Temperature (°F)
-5 -10 -15 -20 -25 -30 -35 -40 -45
-5 -11 -16 -22 -28 -34 -40 -46 -52 -57 -63
40 35 30 25 20 15 10
5
0
MPH
Calm 40 35 30 25 20 15 10
5
0
5
36 31 25 19 13
7
3
0
1
10
15
20
25
30
35
40
45
50
55
60
34 27 21 15
32 25 19 13
30 24 17 11
9
6
4
3
1
0
-4 -10 -16 -22 -28 -35 -41 -47 -53 -59 -66 -72
-7 -13 -19 -26 -32 -39 -45 -51 -58 -64 -71 -77
-2 -9 -15 -22 -29 -35 -42 -48 -55 -61 -68 -74 -81
-4 -11 -17 -24 -31 -37 -44 -51 -58 -64 -71 -78 -84
-5 -12 -19 -26 -33 -39 -46 -53 -60 -67 -73 -80 -87
-7 -14 -21 -27 -34 -41 -48 -55 -62 -69 -76 -82 -89
29 23 16
28 22 15
28 21 14
27 20 13
26 19 12
26 19 12
25 18 11
25 17 10
9
8
7
6
5
4
4
3
-1 -8 -15 -22 -29 -36 -43 -50 -57 -64 -71 -78 -84 -91
-2 -9 -16 -23 -30 -37 -44 -51 -58 -65 -72 -79 -86 -93
-3 -10 -17 -24 -31 -38 -45 -52 -60 -67 -74 -81 -88 -95
-3 -11 -18 -25 -32 -39 -46 -54 -61 -68 -75 -82 -89 -97
-4 -11 -19 -26 -33 -40 -48 -55 -62 -69 -76 -84 -91 -98
Frostbite in >> 30 min. 10 min. 5 min.
WINDCHILL CHART (°C)
Wind
Speed
in
Actual Thermometer Reading (°C)
5
2
-1 -4 -7 -10 -13 -16 -19 -22 -25 -28 -31 -34 -37 -40 -43 -46
Equivalent Temperature (°C)
Km/h
Calm
8
5
3
2
1
0
2
0
-1 -4 -7 -10 -13 -16 -19 -22 -25 -28 -31 -34 -37 -40 -43 -46
-4 -7 -11 -14 -18 -22 -25 -29 -32 -36 -39 -43 -46 -50 -53 -57
16
24
32
40
48
56
64
72
80
88
96
-2 -6 -10 -13 -17 -21 -24 -28 -32 -36 -39 -43 -47 -50 -54 -58 -62
-3 -7 -11 -15 -19 -22 -26 -30 -34 -38 -42 -45 -49 -53 -57 -61 -65
-4 -8 -12 -16 -20 -24 -28 -32 -36 -39 -43 -47 -51 -55 -59 -63 -67
-1 -5 -9 -13 -17 -21 -25 -29 -33 -37 -41 -45 -49 -53 -57 -61 -65 -69
-1 -5 -9 -13 -18 -22 -26 -30 -34 -38 -42 -46 -50 -54 -58 -62 -66 -70
-2 -6 -10 -14 -18 -22 -26 -31 -35 -39 -43 -47 -51 -55 -59 -64 -68 -72
-2 -6 -10 -15 -19 -23 -27 -31 -35 -40 -44 -48 -52 -56 -61 -65 -69 -73
-2 -7 -11 -15 -19 -23 -28 -32 -36 -40 -45 -49 -53 -57 -61 -66 -70 -74
-3 -7 -11 -15 -20 -24 -28 -33 -37 -41 -45 -50 -54 -58 -62 -67 -71 -75
-3 -7 -12 -16 -20 -24 -29 -33 -37 -42 -46 -50 -55 -59 -63 -67 -72 -76
-3 -8 -12 -16 -21 -25 -29 -34 -38 -42 -47 -51 -55 -60 -64 -68 -73 -77
Frostbite in >> 30 min. 10 min. 5 min.
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SAFETY
Safety Labels and Locations
Warning labels have been placed on the snowmobile for your protection.
Read and follow the instructions of the labels and other warnings on the
snowmobile carefully. If any of the labels depicted in this manual differ
from the labels on your snowmobile, always read and follow the
instructions of the labels on the snowmobile.
If any label becomes illegible or comes off, contact your POLARIS
dealer to purchase a replacement. Replacement safety labels are
provided by POLARIS at no charge. The part number is printed on the
label.
Clutch Warning
This warning label is found on the oil bottle:
WARNING
Do not operate engine with
hood or side panels open.
Do not attempt adjustment
with engine running.
Do not operate engine with
the clutch guard removed.
Never run engine with drive
belt removed.
Never service clutches
yourself. See your dealer.
Pressure Cap Warning
This warning label is found on the pressure cap of applicable liquid
cooled models:
WARNING
Do not open hot. Test or replace when changing coolant. Press
down and turn to release cap. 13 PSI
21
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SAFETY
Safety Labels and Locations
“No Passenger” Warning
Reverse Warning
“No Passenger” Warning
Snowmobiles designed for a single rider only have the NO
PASSENGER warning label on the lower left side of the console:
WARNING
This vehicle is designed for operator only. NO PASSENGER
Reverse Warning
The reverse warning label is located on the console, either beside the
steering post or below the windshield:
WARNING
Reverse operation, even at low speeds, can cause loss of control
resulting in serious injury or death. To avoid loss of control,
always:
• Look behind before and while backing up.
• 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:
• Machine stopped and engine at idle, push yellow button on LH
control to reverse. Flashing light on dash indicates reverse
operation.
• Push button again to return to forward.
22
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SAFETY
Safety Labels and Locations
Track Warning
Hot Surface
Warning
Track
Warning
The track warning label is on the
rear tunnel:
WARNING
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.
Hot Surface Warning
The hot surface warning is on the
rear center of the tunnel.
WARNING
Hot Surface
Do Not Touch
Burns may result. Entire top of tunnel may be hot. Install only
accessories specifically approved for this model by POLARIS. Do
not place clothing, bags or cargo on tunnel. Do not cover this
label.
23
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SAFETY
Safety Labels and Locations
Operation Warning
The operation warning label is also located on the console.
Operation Warning
WARNING
• To avoid serious injury or death, read and understand all warnings
and the Owner's Manual before operation. If manual is missing,
contact a POLARIS dealer for a replacement.
• This vehicle is capable of high speeds. Buried objects or uneven
terrain can cause loss of control. Reduce speed and use extreme
caution when operating in unfamiliar terrain.
• Excessive speed, especially at night or with limited visibility, can
result in insufficient time for you to react to terrain changes, to
avoid unexpected obstacles, or to stop safely.
• Never consume alcohol or drugs before or while operating this
vehicle.
• In an emergency, push down the Auxiliary Shut-Off Switch, located
on the top of the throttle control assembly, to stop the engine. Then
pull the brake lever to stop.
• Always wear an approved helmet, eye protection, and adequate
clothing while operating this vehicle.
• This vehicle is designed for adult use only. Check local laws for age
requirements.
(continued on next page)
24
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SAFETY
Safety Labels and Locations
Operation Warning
• When operating with a passenger (on approved models only)
reduce speed and allow extra space for steering and stopping. A
passenger reduces your ability to control the vehicle.
• When operating on hard-packed snow, ice, or when crossing roads,
steering and braking ability are greatly reduced. Reduce speed and
allow extra space to turn or stop.
• 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.
• Repeated stops from high speed may cause fading or sudden loss
of braking ability.
• Parking brake may relax when used for long periods. Do not leave
brake engaged for more than five minutes.
• Before starting engine, check throttle, brake, and steering for proper
operation. Make sure hood and side panels are latched. Be seated
and in position to control the vehicle.
Oil injection system: Use unmixed fuel only. Check oil level when
refueling.
25
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FEATURES
7
6
8
5
4
9
10
3
11
2
12
15
1
13
14
1. Nosepan
2. Skis
8. Operator Seat
9. Taillight
3. Front Bumper
4. Hood
5. Headlight
6. Windshield (accessory)
7. Handlebar
10. Rear Bumper
11. Snow Flap
12. Suspension
13. Track
14. Side Panel
15. Side Panel Fasteners
26
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FEATURES
3
2
4
5
6
1
1. Fuel Filler Cap
2. Instrument Cluster
3. Ignition Switch
10
9
7
8
4. Engine Stop Switch
5. Throttle Control
6. Recoil Starter Handle
7. Brake Lever
8. Parking Brake Lock
RMK
9. Handlebar Grip Warmer
Switch
10. Thumbwarmer Switch
11
13
12
11. Electronic Reverse Button
12. Mode Switch
12 13
9
13. Headlight Dimmer Switch
PRO-RMK/ASSAULT
27
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FEATURES
Storage Bag/Tool Kit
A storage bag and tool kit
is located under the left
side panel between the oil
bottle and console.
Storage Bag
Cargo Storage
Never hang heavy items
or fuel containers from
the rear of the tunnel.
Cargo may be stowed
only under the seat and as
far forward as possible
immediately behind the
seat brace. The maximum
weight capacity for the
tunnel is 15 lbs. (7 kg).
Do not exceed the weight
limit.
Adjustable Headlights
Move the headlight
adjuster to the left to adjust
the headlight beam
Up
upward. Move the adjuster
to the right to adjust the
beam downward.
Down
28
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FEATURES
QUICKDRIVE Belt
The QUICKDRIVE drive system (if equipped) utilizes a drive belt that
exhibits extraordinary performance and service life when the belt is
handled properly before and during installation. Improper handling of
this belt can result in a shortened service life.
Inspect and change the belt at the intervals outlined in the Periodic
Maintenance Table beginning on page 80. See page 101 for inspection
procedures.
Special tools are required to remove and install the QUICKDRIVE belt.
Please see your POLARIS dealer for this service, or refer to the
instructions provided with the purchase of a new belt.
Belt Handling
NO
Crimp
• Store a new belt in original
packaging. Remove only when ready
for installation.
• Avoid belt contact with solvents, oils
or chemical cleaners.
• Do not crimp or bend the belt to a
diameter less than the upper sprocket.
• Do not back-bend the belt.
• Do not twist or flip the belt.
NO
Back-Bend
• Do not use a pry bar or screwdriver to
remove or install the belt.
• Always break in a new belt properly.
See page 67 for belt break-in
procedures.
NO
Twist
29
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FEATURES
Accessories
POLARIS offers a wide range of accessories for your snowmobile to
help make each ride more enjoyable.
Use only POLARIS parts and accessories on your POLARIS
snowmobile. Use of unapproved parts and accessories may result in:
• Non-compliance with government/industry requirements
• Voiding of warranty
• Injury to self or others
This applies, but is not limited to the following areas: brakes, clutches,
fuel systems, and exhaust systems. Exhaust systems are critical safety
areas that must use approved POLARIS parts. Please see your
POLARIS dealer for service.
30
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FEATURES
Fuel Type Selection
Whenever using ethanol, MTBE or other forms of oxygenated
gasolines, the fuel type designation setting must be changed to “Eth” in
the gauge. When using the recommended 91 non-ethanol gasoline,
always select the “91-non” setting.
Whenever in doubt of your fuel
purchase, use the “Eth” setting as
a safeguard.
Use the following procedure to
change the fuel type designation in
the gauge. Refer to the fuel type
selection label located inside the
left side panel.
1. Start the engine.
2. Lock the parking brake.
3. Press and release the
SELECT button or SET
switch until “FUEL” is
displayed in the lower section
of the gauge.
4. Press and hold the SELECT button or SET switch until the desired
fuel type is displayed in the center of the screen.
31
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FEATURES
Detonation Elimination Technology (DET)
The DET system prevents damage to the engine from detonation by
going into an engine protection mode whenever the DET system is
active.
When excessive detonation is detected,
the check engine light will illuminate and
you may notice decreased engine
performance and RPM when the DET
system is activated. In most cases this is
temporary and the operator does not need
to take any action. The engine will return
to its normal performance automatically.
If severe detonation occurs, the check engine light will begin to flash
steadily and the gauge indicator will read “dET” (see illustration). The
engine will enter a limp home mode and RPM will be limited to 6500
RPM. The engine will remain in this mode until it is shut down and
restarted.
Check Engine Light
Indicates
Solid or Flickering
Steady Flashing
Excessive detonation detected
Severe detonation detected, RPM will be limited
32
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FEATURES
Detonation Elimination Technology (DET)
The most likely causes of severe detonation are outlined in the
troubleshooting table below.
DET Troubleshooting
Cause of DET Activation
Poor quality fuel
Solution
Replace with higher quality fuel
Incorrect ethanol/non-ethanol fuel
resistor installed
Verify correct fuel resistor for fuel type
in tank
Low fuel/no fuel in tank
Water in fuel
Refuel with recommended fuel
Replace with recommended fuel
Plugged fuel filter or tank pick-up sock See your POLARIS dealer for service
Alcohol-based fuel additive used with Do not add deicers or additives that
Ethanol fuel
contain any form of alcohol while
using up to 10% Ethanol fuel
Improper engine modifications
Do not modify the engine
Security System (Ignition Lock System)
Your snowmobile has an optional security function that can be activated
by an authorized POLARIS dealer. If you have this feature activated,
you can lock the ignition to prevent unauthorized use when leaving the
snowmobile unattended. A locked system will limit engine speed to
3000 RPM, which prevents clutch engagement, and the snowmobile
will not move when throttle is applied.
If you wish to use this system, see page 41 of the Instrument Cluster
section for security system activation and operating instructions.
33
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FEATURES
Instrument Cluster
Rider Information
Center
Check Engine
Indicator
High Beam
Indicator
Over-Tem-
perature Indi-
cator
Park Brake
Indicator
Reverse
Indicator
Low Oil
Indicator
SELECT
Button
MODE
Button
The instrument cluster contains
indicator lights and the rider
information center. The information
center can be controlled by either
the MODE and SELECT buttons on
the instrument cluster or by the
MODE/SET switch on the left
handlebar or console.
MODE
SET
Mode/Set Switch
(RMK)
NOTICE: Certain products will damage
the lens and other plastic
surfaces. Do not use alcohol
to clean the instrument
cluster. Immediately clean off
any gasoline that splashes on (PRO-RMK/ASSAULT)
the instrument cluster.
Mode/Set Switch
34
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FEATURES
Instrument Cluster
Indicators
Check Engine Indicator
This indicator appears if an EFI-related fault occurs. Do not operate the
snowmobile if this warning appears. Serious engine damage could
result. See your dealer. See page 48 for diagnostic code definitions.
Over-Temperature Indicator
This indicator illuminates to alert the operator that the engine is
overheating. The operator should take action to cool the engine. See
page 92. If the indicator flashes, continued operation could result in
serious engine damage. Stop the engine immediately.
Low Oil Indicator
The low oil indicator light may flicker at times due to oil movement in
the bottle, but when the light comes on and remains on, add the
recommended oil before further operation. See page 71.
High Beam Indicator
The high beam indicator illuminates when the lights are set to high
beam.
Parking Brake Indicator
This indicator illuminates when the parking brake is engaged. It will
also illuminate when the service brake is in use. See page 60.
Reverse Indicator
This indicator flashes when the transmission is in reverse. See page 75.
35
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FEATURES
Instrument Cluster
Rider Information Center
The rider information center is located in the instrument cluster. The
center displays vehicle speed, engine speed, odometer, resettable trip
meters (2), total engine hours of operation, fuel level, engine
temperature and diagnostic display mode.
Setting changes must be made with the engine running or with the
vehicle powered by an external DC power supply connector.
The information center is set to display standard units of measurement
for distance and temperature. To change to metric units, see page 40.
3
1
2
6
4
5
36
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FEATURES
Instrument Cluster
Rider Information Center
1. Information Display Area - This area displays either engine speed
or vehicle speed (whichever is not displayed in the speed display),
engine temperature and maximum vehicle speed. To change the
display, see page 38.
2. Speed Display - The speed display area displays either vehicle
speed or engine speed. To change the display, see page 38.
3. Fuel Gauge - The segments of the fuel gauge show the level of fuel
in the fuel tank. When the last segment clears, a low fuel warning is
activated. All segments including the fuel icon will flash. Refuel
immediately.
Tip: If the fuel icon fails to display, an open or short circuit has occurred in the
fuel sensor circuit. See your dealer.
4. Odometer/Engine Hour Display - This area displays the odometer,
Trip A, Trip B and engine hours. To change the display, see page 39.
5. Battery Power - This indicator illuminates when battery power is
low.
6. Playback Icon - The playback function allows the rider to record
and play back engine speed, vehicle speed and throttle position
sensor information for up to three minutes. The playback icon
flashes while recording. See page 39.
37
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FEATURES
Instrument Cluster
Rider Information Center
Speed Display Area
The speed display area displays either vehicle speed or engine speed.
Vehicle speed is displayed in either miles per hour (MPH) or kilometers
per hour (km/h). Engine speed is displayed in revolutions per minute
(RPM).
1. To change which item displays, first make sure the information
display area is set to display either engine speed or vehicle speed.
2. Press and hold the mode button (on the instrument cluster) or the
mode switch (on the left handlebar) for three seconds.
Information Display Area
This area displays either engine speed or vehicle speed (whichever is
not displayed in the speed display), engine temperature and maximum
vehicle speed. To change the display, press and release the MODE
button or the MODE switch until the desired item is displayed.
38
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FEATURES
Instrument Cluster
Rider Information Center
Odometer/Engine Hour Display Area
This area displays the odometer, Trip A meter, Trip B meter and engine
hours meter.
The odometer displays the total distance traveled by the vehicle since
manufacture. Each trip meter records the distance traveled by the
vehicle on a trip if the meter is reset before each trip. The engine hour
meter displays the total hours the engine has been in operation since
manufacture.
To change the display, press and release the SELECT button or the SET
switch until the desired item is displayed.
To reset a trip meter, press and hold the SELECT button or the SET
switch until the meter resets to zero.
Playback Function
The playback function allows the rider to record and play back engine
speed, vehicle speed and throttle position sensor information for up to
three minutes.
1. To begin recording, simultaneously press and hold the MODE and
SELECT buttons on the instrument cluster for three seconds. The
playback indicator will flash while the instrument cluster is
recording.
2. To play back the recorded data, stop the vehicle and wait for engine
speed to drop below clutch engagement.
3. Simultaneously press and release the MODE and SELECT buttons
on the instrument cluster.
4. Applying the throttle will clear the display and return the instrument
cluster to normal operation.
39
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FEATURES
Instrument Cluster
Rider Information Center
Standard/Metric Display
The odometer and temperature displays can be viewed in either standard
or metric units of measurement. Both displays change if units are
changed. The new settings will remain until changed by the operator.
Change Method 1
1. Press and release the MODE button or MODE switch until engine
temperature displays.
2. Press and hold the MODE button or MODE switch until the units
change.
Change Method 2
1. Press and release the SELECT button or SET switch until the
odometer displays.
2. Press and hold the SELECT button or SET switch until the units
change.
40
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FEATURES
Instrument Cluster
Rider Information Center
Security System (Ignition Lock System)
This system is an optional feature and will not function until it has been
activated by your authorized POLARIS dealer. If you have this feature
activated, you can lock the ignition to prevent unauthorized use when
leaving the snowmobile unattended. A locked system will limit engine
speed to 3000 RPM, which prevents clutch engagement, and the
snowmobile will not move when throttle is applied.
If you wish to use this feature, you must complete all four tasks on the
following pages to have your system activated and to change the
security code to one of your own choosing.
41
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FEATURES
Instrument Cluster
Rider Information Center
Security System (Ignition Lock System)
First Time Use of Your Security System
Perform all tasks in the order shown if you wish to
activate and use the optional security system.
TASK 1: Activate the security system
See your authorized POLARIS dealer to have the optional security system
feature activated in the electronic control unit (ECU).
TASK 2: Lock the System the First Time
1. Start the engine and lock the parking brake.
2. Press and hold the MODE and SEL buttons for 3
seconds, then release. SECURE OFF should be
displayed. If not, repeat this step.
3. Wait until ENTER CODE displays, then press
and release SEL to advance the digit. When “0”
is displayed, press and release MODE to accept
the digit. TIP: If the ENTER CODE screen exits
due to inactivity, repeat step 2.
4. Press and release SEL to advance the second
digit. When “0” is displayed, press and release
MODE to accept the digit.
5. Press and release SEL to advance the third digit.
When “0” is displayed, press and release MODE
to accept the digit.
6. After accepting the third digit, view the display
screen. SECURE ON displays if the system locks.
NOTE: The system is now locked.
7. You must now unlock the system. Proceed imme-
diately to TASK 3.
42
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FEATURES
Instrument Cluster
Rider Information Center
Security System (Ignition Lock System)
First Time Use of Your Security System
TASK 3: Unlock the System
1. When the engine is running, the display will
alternate between SECURE ON and
ENTER CODE. Wait until ENTER CODE
displays, then press and release SEL to
advance the digit. When “0” is displayed,
press and release MODE to accept the
digit.
2. Press and release SEL to advance the second
digit. When “0” is displayed, press and release
MODE to accept the digit.
3. Press and release SEL to advance the third digit.
When “0” is displayed, press and release MODE
to accept the digit.
4. After accepting the third digit, view the display
screen. SECURE OFF displays if the system
unlocks.
NOTE: The system is now unlocked.
5. You must now enter a new security code. Proceed immediately to TASK 4.
TASK 4: Enter Your New Security Code
1. Immediately after locking and unlocking the system, and while SECURE
OFF is displayed, press and release the MODE button to bring up the
ENTER CODE screen.
2. When ENTER CODE displays, use the SEL and MODE buttons to select
and accept each digit of a new personal security code.
3. After accepting the third digit, view the display
screen. The new code and CODE SET will dis-
888
play if the system accepted your new code. You
will not see this display again.
NOTE: Your new code is now set. The system is
NOT locked.
4. Record your new security code in a safe place for future reference.
Record your new personal security code here: __________________
TIP:If you lose your personal security code, see your dealer to have the code
reset to “000”. Then perform TASK 2 through TASK 4 to change the code
to one of your own choosing.
43
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FEATURES
Instrument Cluster
Rider Information Center
Security System (Ignition Lock System)
Locking the System With Your Personal Security Code
1. Start the engine and lock the parking brake.
2. Press and hold the MODE and SEL buttons
for 3 seconds, then release. SECURE OFF
should be displayed. If not, repeat this step.
3. Wait until ENTER CODE displays, then
press and release SEL to advance the digit.
When the first digit of your security code is
displayed, press and release MODE to
accept the digit.
TIP:If the ENTER CODE screen exits due to inactivity,
repeat step 2.
4. Continue to use SEL and MODE to select
and accept the remaining two digits of the
code.
5. After accepting the third digit, view the
display screen. SECURE ON displays if the
system locks. Engine speed is now limited
and the snowmobile cannot be driven.
TIP:When the engine is running, the display will
alternate between SECURE ON and ENTER CODE.
6. If BAD CODE displays, the screen will then
return to the ENTER CODE screen. Repeat
steps 3-5 to re-enter the security code.
44
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FEATURES
Instrument Cluster
Rider Information Center
Security System (Ignition Lock System)
Unlocking the System With Your Personal Security Code
1. When the engine is running, the display
will alternate between SECURE ON and
ENTER CODE. Wait until ENTER
CODE displays, then press and release
SEL to advance the digit. When the first
digit of your security code is displayed,
press and release MODE to accept the digit.
TIP:When the system is locked and engine temperature is above 120° F (49°
C), the correct password must be entered within 60 seconds or the engine
will shut down.
2. Continue to use SEL and MODE to select
and accept the remaining two digits of the
code.
3. After accepting the third digit, view the
display screen. SECURE OFF displays if
the system unlocks.
4. Re-enter your code if BAD CODE
displays.
NOTE: The system is now unlocked.
45
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FEATURES
Instrument Cluster
Rider Information Center
Security System (Ignition Lock System)
Changing to a New Security Code
Any time you wish to change your current security code to a new code,
perform TASK 2 through TASK 4 of the First Time Use of Your
Security System procedure beginning on page 42. Instead of using the
factory default code “000” in TASK 2 and TASK 3, use your current
security code.
Security System Access Quick Reference
Now that you have become familiar with the procedure for locking and
unlocking the system, use the chart below as a quick reference.
Security System Access Quick Reference Chart
Action
Result
Start engine + Lock
parking brake + Press
and hold both MODE +
SELECT (SEL)
Displays ENTER CODE (to lock the system)
Press SELECT (SEL)
Press MODE
Advances a digit on the ENTER CODE screen
Accepts a digit and displays the next digit position (if
any remain) on the ENTER CODE screen
or
Opens ENTER CODE screen if MODE is pressed
immediately after locking and unlocking the system
(to change your security code)
46
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FEATURES
Instrument Cluster
Rider Information Center
Diagnostic Display Mode
The diagnostic display mode is for informational purposes only. Please
see your POLARIS dealer for all major repairs.
The diagnostic mode is accessible only when the check engine warning
indicator is illuminated and a diagnostic code is active.
Do not stop the engine if you want to view the active code (failure
code). Active codes cannot be retrieved if power is interrupted to the
instrument cluster. The codes will become inactive codes if power is
interrupted. Inactive codes are stored in the history of the unit. Please
see your POLARIS dealer to retrieve inactive codes.
Use the following procedure to view active codes.
1. Do not stop the engine.
2. With the brake engaged, press and release the SELECT button or
SET switch to toggle to the diagnostic display mode. When a code
is active, the diagnostic display mode will appear immediately
following the engine hour display.
TIP:When the diagnostic mode is displayed, the check engine warning indicator
will begin to flash.
3. A set of two numbers will appear in the display.
• The 2-6 digit suspect parameter number (SPN) in the information display
area indicates which component is generating the fault code.
• The 1-2 digit failure mode indicator (FMI) number in the odometer area
indicates the fault mode, such as open or short circuit.
4. More than one fault may be active. Press and hold the MODE
button or MODE switch for two seconds to toggle to the next active
code. Repeat until all codes are retrieved.
5. See page 48 for code definitions and failure descriptions.
47
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FEATURES
Instrument Cluster
Rider Information Center
Diagnostic Display Code Definitions
Open Load: There is a break in the wires that lead to the item listed in
the chart (injector, fuel pump, etc.), or the item has failed.
Short-to-Ground: The wire is shorted to ground between the electronic
control unit and the item listed in the chart.
Shorted Load: The wires leading to the item listed in the chart are
shorted together, or the item has shorted internally.
Short-to-Battery: The wire leading from the item listed in the chart to
the electronic control unit is shorted to a wire at battery voltage.
Diagnostic Codes
Component
Condition
Voltage Too High
SPN
FMI
3
Throttle Position Sensor
51
Voltage Too Low
4
Abnormal Rate of Change
Data Erratic, Intermittent or Missing
Voltage Too High
10
2
Vehicle Speed Sensor
84
Intake Air Temperature Sensor
105
3
Voltage Too Low
4
Barometric Pressure Sensor
Engine Temperature Sensor
Voltage Too High
108
110
3
Voltage Too Low
4
Voltage Too High
3
Voltage Too Low
4
Temperature Too High
Engine Overheat Shutdown
Temperature Above Normal Range
Voltage Too High
16
0
15
3
Alternator Power Supply
167
173
Potential (DC Chassis Voltage)
Voltage Too Low
4
Exhaust Temperature Sensor
Voltage Too High
3
Voltage Too Low
4
48
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FEATURES
Instrument Cluster
Rider Information Center
Diagnostic Display Code Definitions
Diagnostic Codes
Component
ECU Memory
Condition
SPN
628
651
FMI
13
5
Checksum/CRC Error
Injector 1 (MAG) (Port Injector)
Injector 2 (PTO) (Port Injector)
Knock Sensor 1
Driver Circuit Open/Grounded
Driver Circuit Short to B+
Driver Circuit Open/Grounded
Driver Circuit Short to B+
Voltage Too Low
3
652
5
3
731
4
Ignition Coil Primary Driver 1 (MAG) Driver Circuit Open/Grounded
1268
1347
1352
5
Fuel Pump Driver Circuit
Driver Circuit Open/Grounded
5
Knock Level Cylinder 1 (MAG)
Maximum Detonation
Correction Limit Reached
0
Knock Above Critical Level
16
0
Knock Level Cylinder 2 (PTO)
Maximum Detonation
Correction Limit Reached
1353
Knock Above Critical Level
Voltage Too Low
16
4
Sensor Supply Voltage 1 (TPS/
TMAP Sensor Power)
3509
3510
3598
Sensor Supply Voltage 2 (Ground
Speed Sensor)
Voltage Too Low
4
ECU Output Supply Voltage 2
(Injection Supply PWR)
Voltage Too High
3
4
3
4
7
5
3
5
3
3
4
2
Voltage Too Low
Throttle Release Signal
Voltage Too High
520194
Voltage Too Low
Throttle Stuck
Chassis Relay
Driver Circuit Open/Grounded
Driver Circuit Short to B+
Driver Circuit Grounded
Driver Circuit Short to B+
Voltage Too High
520208
520215
524007
Exhaust Valve Solenoid
Fuel Type Selected
Voltage Too Low
Signal Out Of Range
49
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THE PERFECT FIT
Suspension Adjustments
Factory settings, combined with user adjustments to the rear track shock
spring (RTSS), should be all that’s necessary to provide the best riding
experience for most riders. The primary adjustment for overall vehicle
balance is RTSS preload. Perform this adjustment first.
Always perform shock spring preload adjustments with the weight of
the vehicle removed from the shock and with the shock at full extension.
NOTICE: Never adjust spring preload to an installed length longer than the
maximum or shorter than the minimum lengths in the following chart.
Damage to the suspension could result. Never exceed one inch (2.54
cm) of preload beyond the factory settings. When decreasing preload,
make sure at least two turns of preload are holding the retainer
against the spring.
Spring Type
Maximum
Installed Length
MinimumInstalled
Length
RMK Factory Spring
10 3/4" (27.3 cm)
11" (28 cm)
9 5/8" (24.5 cm)
9 3/4" (24.8 cm)
9 3/8" (23.8 cm)
9 7/8" (25 cm)
PRO-RMK Factory Spring
ASSAULT RMK Factory Spring
250# Optional Heavy Spring
11" (28 cm)
10 7/8" (27.6 cm)
Installed Length
Measurement
50
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THE PERFECT FIT
Suspension Adjustments
For riders who weigh 160-220 lbs. (73-100 kg), test ride at factory
settings, then make fine-tuning adjustments. See page 52.
For riders outside the 160-220 lbs. (73-100 kg) weight range, adjust the
factory-set preload to the following installed lengths as a starting point,
then test ride before making fine-tuning adjustments. Do not exceed the
minimum and maximum installed length requirements. See page 50.
TIP:If adjustments to the factory-installed springs are not sufficient for riders
over 300 lbs. (136 kg), optional heavy springs are available. Please see
your POLARIS dealer.
Initial RTSS Preload Settings
(Measure spring length with suspension off the ground)
Rider Weight
Model
Installed Length
For Factory-Installed Springs
Under 160 lbs. Under 73 kg
RMK/PRO-RMK
ASSAULT RMK
10 3/4"
10 7/8"
*10 1/4"
27.3 cm
27.6 cm
*26 cm
160-220 lbs
73-100 kg
RMK/ASSAULT
RMK
PRO-RMK
*10 3/8" *26.4 cm
220-280 lbs.
280-340 lbs.
100-127 kg
127-154 kg
RMK/PRO-RMK
ASSAULT RMK
RMK/PRO-RMK
ASSAULT RMK
10 1/8"
10"
25.7 cm
25.4 cm
24.8 cm
24.1 cm
9 3/4"
9 1/2"
*Factory Setting
For Optional 250-Pound Heavy Springs
250-300 lbs.
300-350 lbs.
113-136 kg
136-159 kg
ALL
ALL
10 1/8"
10"
25.7 cm
25.4 cm
51
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THE PERFECT FIT
Suspension Adjustments
Fine-Tuning Your Suspension Set-Up
The primary adjustment for overall vehicle balance is RTSS preload.
Adjust the factory-set preload to the recommended setting for your
weight and then test ride. Additional minor adjustments can then be
made to the spring preload to adjust the feel of the vehicle. Do not
exceed the minimum and maximum installed length requirements. See
page 50.
For more ski lift (transfer), reduce spring preload by increasing the
installed length. Rotate the spring 1-2 full turns counter-clockwise
(when viewed from bottom). This will enhance maneuverability,
making the snowmobile more “flickable” although it may hinder
climbing performance.
For less ski lift (transfer), increase spring preload by reducing the
installed length. Rotate the spring 1-2 full turns clockwise (when viewed
from bottom). This will improve climbing ability and rider control.
To control the overall balance of the vehicle use the following guideline:
• More rear track shock spring preload increases ski pressure. Less
preload decreases ski pressure.
• Spring preload can affect bottoming resistance. More preload means
less bottoming. Less preload means a softer ride (and more
bottoming). Both adjustments will affect overall balance and ski
pressure.
After adjusting RTSS preload to your satisfaction, the front track shock
(FTS) spring preload and independent front suspension (IFS) spring
preload can also be adjusted. See page 54.
52
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THE PERFECT FIT
Suspension Adjustments
Shock Compression Damping (RMK/ASSAULT RMK)
The primary adjustment for overall vehicle balance is RTSS preload.
Perform this adjustment first. See page 50. After adjusting RTSS
preload to your satisfaction, compression damping adjustments can be
made to control ride quality and bottoming resistance.
800 RMK Damping
Make the adjustments in half-turn
increments, then test ride.
Screw
To stop bottoming, turn the damping
screw clockwise one half-turn, then test
ride. Repeat the adjustment until
bottoming stops and the desired ride
quality is achieved.
ASSAULT RMK Damping
Compression damping can be adjusted at
Stiffer
Softer
the front suspension and at the rear track
shock. Make adjustments in 2-click
increments, then test ride. When adjusting
the front suspension, always adjust both
clickers equally.
To stop bottoming of the front or rear
suspension (stiffer ride), rotate the
clicker(s) clockwise two clicks (as viewed
from the top of the clicker), then test ride.
Repeat the adjustment until bottoming
stops and the desired ride quality is
achieved.
For a more plush ride at the front or rear
suspension, rotate the clicker(s) counter-
clockwise two clicks, then test ride.
Repeat the adjustment until the desired
ride quality is achieved.
53
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THE PERFECT FIT
Suspension Adjustments
Independent Front Suspension and Front Track Shock
Spring Preload (RMK/PRO-RMK)
Factory settings, combined with user adjustments to the rear track shock
spring, should be all that’s necessary to provide the best riding
experience for most riders. The primary adjustment for overall vehicle
balance is RTSS preload. Perform this adjustment first. See page 50.
After adjusting the preload, and if desired, additional adjustments can be
made to the independent front suspension and front track shock preload.
When adjusting the front suspension, be sure the springs on both sides
of the vehicle are at the same adjustment.
Always perform shock spring preload adjustments with the weight of
the vehicle removed from the shock and with the shock at full extension.
NOTICE: Never exceed one inch (2.54 cm) of preload beyond the factory
settings. When decreasing preload, make sure at least two turns of
preload are holding the retainer against the spring.
For a softer ride on rough, washboard surfaces, reduce front track shock
(FTS) spring preload by 1-2 turns.
To improve corner stability, increase front suspension (IFS) spring
preload by 1-2 turns on both sides of the vehicle.
NOTICE: IFS spring installed length must always be set at least 1/4 inch (6 mm)
less than the free length.
54
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THE PERFECT FIT
Handlebar Adjustments
Loosen top bolts to adjust
handlebar angle
Loosen bottom
bolts to adjust
handlebar position
(if equipped)
Handlebar Position (if equipped)
1. Loosen the four bolts on the bottom of the adjuster block. If
necessary, pry the blocks apart with a screwdriver.
2. Adjust the handlebar forward or rearward to the desired position.
3. Tighten the bolts.
Handlebar Angle
1. Loosen the four bolts on the top of the adjuster block. If necessary,
pry the blocks apart with a screwdriver.
2. Adjust the handlebar forward or rearward to the desired angle. Be
sure handlebars, brake lever and throttle lever operate smoothly and
do not hit the gas tank, windshield or any other part of the machine
when turned fully to the left or right. If necessary, loosen the set
screws for the left and right controls, rotate the controls slightly,
then tighten the set screws to the proper torque.
NOTICE: Do not stretch wires while adjusting the controls. Stretching the wires
could damage the handwarmers.
• Right control torque: 27 in. lbs. (3.05 Nm) +/- 10%.
• Left control torque (RMK): 24 in. lbs. (2.7 Nm) +/- 10%.
• Left control torque (PRO RMK): 70 in. lbs. (8 Nm) +/- 10 in. lbs.
3. Tighten the bolts.
55
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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.
Item
See Page
Drive Belt or QUICKDRIVE Belt
Steering System
101
61
Recoil Rope
61
Coolant Level
91
Chaincase Oil Level
85
Injection Oil Level
71
Parking Brake Lock/Brake Lever/Brake System
Auxiliary Shut-Off Switch (Engine Stop Switch)
Ignition Switch
59, 60, 96
62
62
Headlight/Taillight/Brakelight
Suspension Mounting Bolts
Skags (Wear Bars)
62
57
111
57
Ski Saddle and Spindle Bolts
Hood and Side Panel Fasteners
Throttle Lever/Safety Switch
Rear Wheel Idler Bolts
83
72, 73
107
62
Tether Switch/Strap (if equipped)
Track Alignment/Condition
Rail Slide Condition
61, 108
112
56
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PRE-RIDE INSPECTIONS
Pre-Ride Suspension Inspection
Loose nuts and bolts can reduce your 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.
Item
See Page
Check suspension mounting bolts for tightness.
Check rear idler wheel bolts for tightness.
Check rear idler adjusting bolt locknuts for tightness.
Check front torque arm limiter strap condition.
Check rail slide condition.
--
107
--
--
112
106
111
--
Check track tension.
Check ski runner/skag condition.
Check ski spindle bolts for tightness.
Check tie rod end nuts for tightness.
--
57
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PRE-RIDE INSPECTIONS
Before Starting the Engine
Before starting the engine, always refer to all safety warnings pertaining
to snowmobile operation. Never start the engine without checking all
vehicle components to be sure of proper operation.
WARNING! Operating the vehicle with worn, damaged, or malfunctioning
components could result in serious injury or death. Never start the engine
without checking all vehicle components to be sure of proper operation.
Read 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 snowmobiling experience.
Throttle Lever
The throttle and brake are the primary controls of your snowmobile.
Always make sure both are functioning properly.
Squeeze the throttle lever to make sure it compresses evenly and
smoothly. When released, the lever should immediately return to the
idle position without binding or hesitation. If the throttle does not
function smoothly, or if you discover excessive lever freeplay, DO NOT
start the engine. Have the throttle serviced immediately.
Throttle Safety Switch
Test the throttle safety switch system before the snowmobile is operated.
See page 72.
58
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PRE-RIDE INSPECTIONS
Before Starting the Engine
Brakes
Always check the following items for proper operation before starting
the engine.
Brake Lever Travel
Squeeze the brake lever. It
should move no closer to the
handgrip than 1/2 inch (1.3
1/2 in. (1.3 cm)
cm). A smaller distance
indicates low brake fluid
level or air in the hydraulic
system. Refer to the brake
bleeding information on page
98 or see your dealer for
service.
Lever Feel
If the brake lever feels “spongy” when squeezed, check the brake fluid
level and condition. Add fluid as needed. See page 97.
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
serviced at the first sign of sponginess.
59
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PRE-RIDE INSPECTIONS
Before Starting the Engine
Parking Brake Lever Lock
Use the parking brake lever lock
only when you want the
snowmobile to remain
4
3
2
1
stationary; for example, when
parked on an incline for a period
of five minutes or less.
1. Brake Lever
2. Parking Brake Lever Lock
2
3
4
3. Master Cylinder Reservoir/
Cover
1
4. Fluid Level Indicator
Lock Engagement
To engage the lock, squeeze the
brake lever tightly and push
forward on the lock. Hold the
lock forward while releasing the
brake lever.
TIP:If the brake lever is squeezed tightly enough, the lock will move freely into
place. Do not force the lock or it may break.
The parking brake light on the gauge will light up if the parking brake
lever lock is set while the engine is running. It will also be lit when the
service brake is in use. If the parking brake light does not come on when
the parking 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 unlocked position.
WARNING! If the parking brake lever lock is partially or entirely engaged while
riding, the brakes may overheat, resulting in brake damage. In extreme cases it
could cause a fire, which could result in serious injury or death. Always ensure
that the lever lock is completely disengaged before operating the snowmobile.
60
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PRE-RIDE INSPECTIONS
Before Starting the Engine
Steering System
WARNING! Ice and snow build-up may interfere with the steering of your
snowmobile, 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
is encountered, remove ice and snow build-up that may be obstructing
the steering linkage.
Track
Track damage or failure caused by operation on ice or poor lubrication
conditions voids the track warranty.
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.
WARNING! Use of traction products such as studs increases the possibility of
track damage and/or failure. Driving at high speeds for extended periods of time
in marginal lubrication could severely damage track rods, break track edges,
and cause other track damage. Examples of marginal lubrication would include
frozen bodies of water without snow cover, icy trails, and no-snow conditions.
Hood and Side Panel Fasteners
The hood and side panels of the snowmobile protect the operator from
moving parts. Never operate a snowmobile with the hood or side panels
open or removed. Always ensure that the hood and side panels are
securely in place before starting the engine.
Seat Latches
If your snowmobile is equipped with a removable seat, ensure that the
seat is properly installed and securely latched before each use of the
snowmobile.
Recoil Rope
Inspect the recoil rope and handle for excessive wear, and make sure the
knot securing the rope inside the handle is secure. If excessive wear is
found, see your POLARIS dealer for replacement.
61
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PRE-RIDE INSPECTIONS
Start the Engine and Check
Before starting the engine, always refer to all safety warnings pertaining
to snowmobile operation. Never engage the starter when the engine is
running. Never start the engine without checking all vehicle components
to be sure of proper operation. See Before Starting the Engine beginning
on page 58.
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.
Ignition Switch
Make sure the engine stops when the ignition switch is turned to OFF.
Tether Switch (if equipped)
If your snowmobile has a tether switch, remove the tether from the
switch to make sure the engine stops immediately.
Lighting
Check the headlight (high and low beam), taillight, and brake light.
Replace burned out lamps before operating.
Mirrors (if equipped)
Adjust the mirrors so they can be used to their full advantage.
Operating Area
Before driving away, check your surroundings. Be aware of obstacles
and make sure bystanders are a safe distance from the snowmobile.
62
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OPERATION
Starting the Engine
NOTICE: Engaging the starter when the engine is running WILL result in serious
engine damage, especially if the transmission is in reverse. Never
engage the starter when the engine is running.
1. Turn the key to the ON position.
2. Pull the engine stop switch up to the RUN position.
3. If equipped with electric start, turn the key to START to crank the
engine. Release the key to the ON position when the engine starts.
4. If not equipped with electric start, grasp the starter handle and pull
slowly until the recoil engages; then pull abruptly to crank the
engine.
TIP:Don't pull the starter rope to the fully extended position and don't allow it to
snap back into the housing. Damage may result.
5. If the engine does not start after several attempts, slightly depress
the throttle no more than 1/4 inch (2.54 cm) open while cranking the
engine. When the engine starts, immediately release the throttle.
CAUTION! To avoid injury and/or engine damage, do not operate the electric
starter or pull-rope starter while the engine is running.
NOTICE: Operating the vehicle immediately after cold starting could cause
engine damage. Allow the engine to warm up for several minutes
before operating the vehicle. If cold drive-away is attempted, the
engine RPM may stumble slightly to protect the engine.
63
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OPERATION
Starting the Engine
Restarting an Engine
If the rider stops the engine by pushing the engine stop switch down,
restart the engine using the normal starting procedure. If the engine fails
to start using the normal procedure:
1. Push the engine stop switch down to the OFF position.
2. Turn the key to the OFF position.
3. With both switches OFF, squeeze and hold the throttle in the wide
open position.
4. Crank the engine several times to clear the engine.
5. Release the throttle.
6. Restart the engine using the normal starting procedure.
64
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OPERATION
Break-In Period
Engine Break-In
Always follow these recommended break-in procedures for new or
rebuilt engines. The first tank of fuel is considered the break-in period
for the engine.
Premix the first tank of fuel and fill the oil reservoir as outlined below.
Oil added to the fuel and oil injection systems will provide the necessary
engine lubrication.
Oil Recommendations
First Tank of Fuel: POLARIS VES 2-Cycle Oil
After Break-in:
POLARIS VES 2-Cycle Oil
See page 122 for the part numbers of POLARIS products.
Never mix brands of oil. Serious chemical reactions can cause injection
system blockage, resulting in serious engine damage. Oils may also be
incompatible and the result could be sludge formation, filter blockage,
and reduced cold weather flow rates. All POLARIS oils are compatible
with each other.
Initial Fuel Premix
Always premix fuel in 5-gallon (19-liter) increments in a separate fuel
container. Never add oil directly to the fuel tank.
Fuel
VES 2-Cycle Oil
Ratio
Each 5 gal. (19 l)
16 oz. (473 ml)
40:1
65
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OPERATION
Break-In Period
Engine Break-In
Excessive heat build-up during the first three hours of operation will
damage close-fitted engine parts. Do not operate at full throttle or high
speeds for extended periods during the first three hours of use. Vary the
throttle openings and vehicle speeds to reduce friction on all close-
fitting machined parts, allowing them to break in slowly without
damage.
NOTICE: Use of any lubricants other than those recommended by POLARIS
may cause serious engine damage. We recommend the use of
POLARIS lubricants for your vehicle.
Drive with extra caution during the break-in period. Perform regular
checks on fluid levels, lines, and all other important areas of the
snowmobile.
Oil Injection System
Always check and fill the oil bottle when refueling. See page 71.
NOTICE: Serious engine damage can occur without the proper lubrication.
Check the oil bottle level often during the first tank of fuel. If the oil
level doesn't go down, contact your dealer immediately.
66
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OPERATION
Break-In Period
Drive Belt/QUICKDRIVE Belt Break-In
The length of the break-in period varies depending on the type of drive
system. The break-in period for a new drive belt is 30 miles (48 km).
The break-in period for a new QUICKDRIVE belt is 100 miles (160
km).
• Vary the throttle position and limit full throttle use.
• Always take time to warm up the belt and driveline prior to operating
the snowmobile. Free the track and skis from the ground before
engaging throttle.
Break-In Requirements Specific to the QUICKDRIVE Belt
• During the 100 miles (160 km) of belt break-in, the rider will hear a
sound made by the drive system. After the break-in period, the sound
will become similar to that of a traditional chaincase.
• Improper track tension can result in track ratcheting, which will affect
QUICKDRIVE belt durability. Always maintain proper track tension.
See page 106.
• During the break-in period, this belt sheds a fiber-type material in and
around the drive system. Use a dry shop towel to clean the residue.
• Stop occasionally and allow the snowmobile to cool after high
throttle/high track load events. This will help the QUICKDRIVE belt
achieve maximum performance and it will also break in the engine,
drive belt and sprockets properly.
• On-trail break-in should be performed at speeds no more than 50
MPH (80 km/h).
• Always be cautious when jumping and landing a snowmobile. Avoid
“power-on” landings. Damage caused to any component due to
improper use or abuse is not covered by warranty.
67
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OPERATION
Track Warm-Up
WARNING! A loose track or flying debris could cause serious injury or death.
Stand clear of the front of the snowmobile and the moving track. Never hold the
snowmobile up or stand behind it while warming up the track. Do not use
excessive throttle during warm-up or when the track is free-hanging. Use a
stable rear support.
WARNING! Use of traction products such as studs, ice growsers, etc. will
increase the possibility of track damage and/or failure. This could cause loss of
control, resulting in serious injury or death. Always inspect for track damage
before operating the snowmobile.
Follow these steps to ensure proper warm-up of 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 about 4 inches
(10 cm) off the ground.
2. Start the engine and allow it to warm up two to three minutes.
3. Depress the throttle abruptly and allow the track to rotate several
revolutions.
TIP:It will take longer to warm up the track sufficiently during colder outdoor
temperatures.
4. Release the throttle, apply the brakes, shut off the engine and lower
the snowmobile to the ground.
5. Grasp the skis by their front loops and move them from side to side
to loosen snow and ice.
Slide Rail and Track Cooling
NOTICE: Inadequate cooling and lubrication will lead to overheating of the slide
rail and track, resulting in premature wear and failure. Reduce speeds
and frequently drive into fresh snow to allow adequate cooling and
polishing of the slide rail and track surfaces. Avoid operating on ice,
hard-packed surfaces or roads.
68
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OPERATION
Fuel
WARNING
Gasoline is highly flammable and explosive under certain conditions.
• Always exercise extreme caution whenever handling gasoline.
• Always refuel outdoors or in a well-ventilated area.
• Always turn off the engine before refueling.
• Do not overfill the tank. Do not fill the tank neck.
• Do not smoke or allow open flames or sparks in or near the area where
refueling is performed or where gasoline is stored.
• If gasoline spills on your skin or clothing, immediately wash it off with soap
and water and change clothing.
• Never start the engine or let it run in an enclosed area. Engine exhaust fumes
are poisonous and can cause loss of consciousness or death in a short time.
WARNING
The engine exhaust from this product contains chemicals known to cause
cancer, birth defects or other reproductive harm. Operate this vehicle only
outdoors or in well-ventilated areas.
69
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OPERATION
Fuel Recommendation
For peak performance, POLARIS recommends the use of 91 octane fuel
or higher, with no ethanol. Although 87 octane fuel is usable, some
engine performance will be lost and fuel economy will decrease. Do not
use lower than 87 octane fuel. Do not use fuel containing more than
10% ethanol. Never use E85 fuel in your snowmobile.
NOTICE: Operating with obstructed fuel systems will result in serious engine
damage. Perform maintenance as recommended.
Prolonged exposure to petroleum based products may damage paint.
Always protect painted surfaces when handling fuel.
Fuel System Deicers
If you use non-ethanol fuel (sometimes labeled “non-oxygenated”),
POLARIS recommends the regular use of isopropyl-based fuel system
deicer. Add one to two ounces per gallon (8-16 ml per liter) of gasoline
to prevent damage resulting from fuel system icing. Never use deicers
or additives containing methanol. POLARIS recommends the use of
Carbon Clean. See page 122 for the part numbers of POLARIS
products.
If you use fuel with up to 10% ethanol (sometimes labeled
“oxygenated”) do not add deicers or additives that contain any form of
alcohol.
70
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OPERATION
Oil
Low Oil Level
Always maintain the oil level between
the “add” mark and the bottle neck.
Do not fill the bottle neck. See page
65 for oil recommendations.
“Add”
Mark
1. Immediately stop the engine if the
low oil indicator light comes on.
2. Open the left side panel.
3. View the oil level in the oil bottle.
4. Add oil as needed before operating.
NOTICE: Operating the snowmobile without adequate engine lubrication can
result in serious engine damage. Always check the oil level when
refueling. Add oil as needed.
The oil bottle cap is vented to allow proper oil flow. See your POLARIS
dealer for recommended replacement parts.
71
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OPERATION
Engine Stop Switch
Push down on the engine stop
switch to ground out the
ignition and stop the engine
quickly. Pull the switch up to
the ON position to allow
restarting.
Stop
Switch
Throttle Safety Switch
The throttle safety switch is designed to stop the engine whenever all
pressure is removed from the throttle lever and the throttle cable or
valves do not return to the normal closed position.
WARNING! Operating the snowmobile with a faulty throttle safety switch can
result in serious injury or death in the event of an accident. If the throttle safety
switch does not shut off the engine during a carburetor/throttle system
malfunction, immediately push down the engine stop switch. Do not start the
engine again until the malfunction has been corrected by your dealer.
Test the throttle safety switch system
daily before operation.
1. Sit on the seat.
2. Start the engine and allow it to idle.
3. Hold the throttle lever pin
stationary by exerting pressure on
the pivot pin in the direction shown
in the illustration.
4. Apply a slight amount of throttle. A properly functioning switch
must shut down the engine.
72
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OPERATION
Throttle Lever
WARNING! An improperly functioning throttle lever may cause erratic
snowmobile behavior and loss of control, which could result in serious injury or
death. If the throttle lever does not work properly, DO NOT start the engine.
If the engine stops abruptly when the throttle lever is released:
1. Turn the ignition switch to OFF.
2. Visually inspect the throttle cable and carburetor/throttle body to
determine what caused the safety switch to activate.
3. Test the throttle lever by compressing and releasing it several times.
The lever and cable must return to the idle position quickly and
completely.
4. If the throttle lever operates properly, turn the ignition switch on and
go through normal starting procedures.
5. If the engine doesn't start, take the snowmobile to an authorized
POLARIS dealer for service.
Excessive freeplay in the throttle cable may cause the safety switch to
activate, preventing the engine from starting. If this occurs, return the
snowmobile 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 wire
harness. When these switches are disconnected, the ignition key switch
must be used to shut off the engine. DO NOT continue to operate the
snowmobile with the throttle safety switch disconnected. Return the
snowmobile to an authorized POLARIS dealer for service as soon as
possible.
73
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OPERATION
Electronic Reverse (PERC)
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 attempted when the engine is operating above idle
speed.
• Shift to or from reverse only when the snowmobile is stopped and when
engine speed is at idle.
• Look behind the vehicle before and while backing.
• Avoid sharp turns.
• Apply throttle slowly.
Electronic reverse will activate only if the engine RPM is below 4000.
NOTICE: Engaging the starter when the engine is running WILL result in serious
engine damage, especially if the transmission is in reverse. Never
engage the starter when the engine is running.
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OPERATION
Electronic Reverse (PERC)
Engaging Reverse
1. Stop the snowmobile and leave the engine idling.
2. Make sure the area behind your vehicle is clear.
3. Push the yellow reverse button on the left-hand control for one
second, then release. The engine will automatically reduce RPM
and start a reverse rotation. A flashing reverse light on the
instrument panel will indicate that the transmission is in reverse.
4. Apply the throttle slowly to make sure the transmission is in
reverse.The maximum engine RPM will be 6000 when in reverse.
TIP:If the engine stops running, the snowmobile will be in forward gear when it's
restarted.
Disengaging Reverse
1. Stop the snowmobile and leave the engine idling.
NOTICE: Engaging the starter when the engine is running WILL result in serious
engine damage, especially if the transmission is in reverse. Never
engage the starter when the engine is running.
2. Push the yellow reverse button for one second and release. The
engine will slow and begin to rotate forward. The light on the
instrument panel will shut off.
3. Apply the throttle slowly to make sure the transmission is in
forward.
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OPERATION
Emergency Stopping
The following chart lists methods for stopping the snowmobile in the
event of an emergency. See page 72 for more information about the
engine stop switch and throttle safety switch.
SYSTEM
Ignition Switch
WHAT IT DOES
Interrupts ignition circuit
Brake
Slows jackshaft
Engine Stop Switch
Throttle Safety Switch
Tether Switch (Option)
Interrupts ignition circuit
Interrupts ignition circuit
Interrupts ignition circuit
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OPERATION
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 inches (10 cm) off the ground.
Remove the key and cover the snowmobile.
Towing
For your safety, do not attempt to use a tow hitch until you've read the
following warnings and understand the proper hitch functions.
WARNING! Objects towed with a rope have no braking power and can easily
collide with the rear of the snowmobile or other objects, resulting in serious
injury or death. DO NOT tow toboggans, sleds, saucers, or any type of vehicle
with a rope. Only a stiff metal pole connecting the towed object and the tow hitch
on the snowmobile should be used. If passengers are to be towed on a
toboggan or sled, make sure the pole is at least four feet (1.2 meters) long to
prevent any possibility of contact between the snowmobile's track and a person
riding in the towed object.
WARNING! Braking distances increase when towing loads. Slow down to
maintain control of the snowmobile.
If the snowmobile becomes inoperable and must be towed, and if it isn't
possible to use a rigid tow bar, attach the tow rope to the ski spindles
(not to the ski loops) to prevent damage to the steering components.
Remove the drive belt before towing, and have someone ride on the
towed snowmobile to operate the brake and steering when necessary.
NOTICE: Towing a disabled snowmobile with the drive belt in place can result in
serious damage to the engine and drive system. Always remove the
drive belt from a disabled snowmobile before towing.
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MAINTENANCE
Emission Control Information
Any qualified repair shop or qualified person may maintain, replace, or
repair the emission control devices or systems on your snowmobile.
Emission Control Label
Your snowmobile is equipped at the time of sale with an emission
control information (ECI) label and a factory-installed emissions
information hangtag. These items are required by U.S. Environmental
Protection Agency regulations. The ECI label is permanently affixed to
either the right side of the tunnel or the engine recoil cover. The ECI
label should not be removed, even after you purchase the snowmobile.
You may remove the factory-installed emissions information hangtag,
which is intended solely for your use in making a purchasing decision.
Emission Control Maintenance Requirements
Your snowmobile is certified to operate on gasoline with a minimum
octane level of 87 (R+M)/2. If your snowmobile is equipped with a
check engine light and it comes on, you must take your snowmobile to a
qualified dealer for diagnostic service. Specifications and adjustments
for engine tune-ups are located in the Service Manual, which is
available to your qualified service technician. Reverse (if equipped)
must not be engaged during engine tune-ups.
Owner's Responsibilities
Please read the Snowmobile Engine Emissions Limited Warranty, and
read the maintenance section of your owner's manual. You are
responsible for ensuring that the specified maintenance is performed.
POLARIS recommends that you contact an authorized POLARIS dealer
to perform any service that may be necessary.
Non-ionizing Radiation
This vehicle emits some electromagnetic energy. People with active or
non-active implantable medical devices (such as heart monitoring or
controlling devices) should review the limitations of their device and the
applicable electromagnetic standards and directives that apply to this
vehicle.
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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 135.
The recommended maintenance schedule on your snowmobile calls for
service and maintenance inspections at 150 miles (240 km), 500 miles
(800 km) and 1000 miles (1600 km). These inspections should be
performed by a qualified service technician. For continued optimum
performance and component life, continue maintenance checks at 1000
mile (1600 km) intervals.
All necessary replacement parts and labor incurred, with the exception
of authorized warranty repairs, become the responsibility of the
registered owner. If, during the course of the warranty period, part
failures occur as a result of owner neglect in performing recommended
regular maintenance, the cost of repairs are the responsibility of the
owner.
Personal safety is critical when attempting to service or make
adjustments to your snowmobile. If you're not familiar with safe service
or adjustment procedures and the use of tools, or if you don't feel
comfortable performing these tasks yourself, contact an authorized
POLARIS dealer for service.
NOTICE: Hot components can cause damage to plastic. Always make sure the
exhaust system and engine have cooled before tipping the
snowmobile on its side for service or inspection.
79
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MAINTENANCE
Periodic Maintenance Interval Table
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 genuine
POLARIS parts, available from your POLARIS dealer.
Item
See
Page
Frequency
150 mi.
500 mi.
1000 mi.
2000 mi.
Pre-
(240 km) (800 km) (1600 km) (3200 km)
Season
CLUTCH
Clutch Alignment Offset
(without belt)
100
I
I
I
Drive Belt (Condition)
QUICKDRIVE Belt
Clutches
101
101
100
--
I
I
I
I
I
R
C
I
I
I
I
C
I
C
I
Belt Tension
I
I
Clutch Sheaves
100
I
I
I
ENGINE/COOLING
Engine Mounts
Recoil Rope
--
--
I
I
I
I
I
I
I
I
Cylinder Head Bolts
Cylinder Base Nuts
Ignition Timing BTDC
VES System
--
I
I
I
--
I
I
I
--
I
I
I
--
C
I
C
I
C
R
I
I
I
I
Coolant Level
91
--
Coolant Hose
I
I
Coolant Circulation
Coolant Leaks
Spark Plugs
--
I
I
I
--
I
I
I
I
I
I
I
89
94
94
I
I
R
I
Exhaust Pipe
Exhaust Retaining
Springs
I
I
I
I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)
C - Clean
R - Replace
L - Lubricate
80
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MAINTENANCE
Periodic Maintenance Interval Table
Item
See
Page
Frequency
150 mi.
500 mi.
1000 mi.
2000 mi.
Pre-
(240 km) (800 km) (1600 km) (3200 km)
Season
BRAKES
Hose Routing
Hose Condition
Fluid Leaks
--
--
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
--
Brake Pads
96
Brake Disc
--
Parking Brakes
Brake System
Brake Fluid
60
59, 96
97
I
FUEL MANAGEMENT
I
Idle RPM
--
73
--
I
I
I
I
I
I
Throttle Lever
I
I
I
I
I
Oil Pump Lever
(synchronize)
Throttle Position Sensor
Fuel Lines
--
I
I
I
I
I
I
87
87
90
90
--
Fuel Filter
R - Every 2000 mi. (3200 km) or Every 2 years
R
Oil Filter
Oil Lines
I
I
I
I
I
I
Air Box
I
I
ELECTRICAL
Auxiliary Shut-Off
Switch
62
I
I
I
I
I
Throttle Safety Switch
Ignition Switch
Taillight
72
--
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
62
62
62
Brakelight
Headlight
81
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MAINTENANCE
Periodic Maintenance Interval Table
Item
See
Page
Frequency
150 mi.
500 mi.
1000 mi.
2000 mi.
Pre-
(240 km) (800 km) (1600 km) (3200 km)
Season
CHASSIS
Ski Toe Alignment
--
--
I
I
I
I
I
I
Suspension Mounting
Bolts
I
I
Bolt Torques
See your dealer every 1000 mi. (1600 km) for inspection
Rear Suspension
Fasteners
--
I
I
I
I
I
Steering Fasteners
--
--
--
I
I
I
I
R
I
C
Suspension Shock Oil
Cooling Fins and
Shroud
I
I
I
Drive Shaft Bearing
Skags (Wear Bars)
Ski Saddle/Spindle Bolts
Drive Chain Tension
86
111
--
L
I
L
I
L
I
I
I
I
I
I
I
I
I
I
I
I
I
95
83
I
I
I
Hood and Side Panel
Fasteners
I
I
I
Rear Wheel Idler Bolts
Idler Bolt Jam Nut
Camber Alignment
Handlebar Centering
Tether Switch and Strap
Track Alignment
107
107
--
I
I
I
I
I
I
I
I
I
I
I
I
I
--
I
I
I
I
I
I
I
62
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
I
108
106
--
Track Tension
Front Limiter Strap
Rail Slide Condition
Chaincase Oil
112
85
I
R
I
R
I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)
C - Clean R - Replace L - Lubricate
Bolt Torque Inspection
To maintain proper chassis performance, see your POLARIS dealer for
a bolt torque inspection every 1000 miles (1600 km).
Item
Description
Engine Mounting Bolts
Chaincase Mounting Bolts
Remove drive clutch and resonator for access to all bolts
Two (2) TORX-head bolts on forward side of chaincase
Four (4) rear chaincase nuts
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MAINTENANCE
Hood/Side Panel
The hood and side panels of the
snowmobile protect the operator
from moving parts. Never
operate a snowmobile with the
hood or side panels open or
removed. Always ensure that
the hood and side panels are
securely in place before starting
the engine.
Strap
To open a side panel, rotate the
two 1/4-turn fasteners at the
upper edges of the side panel.
Release the side panel strap at
the lower edge of the panel.
1/4-Turn Fasteners
To remove an open side panel,
pull the panel outward to release
the tabs at the lower edge of the
panel.
Removing the hood is not recommended. Any service requiring the
removal of the hood should be performed by an authorized POLARIS
dealer.
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MAINTENANCE
Lubrication
Rear Suspension
Lubricate the suspension pivot shafts with POLARIS All Season Grease
at the intervals outlined in the Periodic Maintenance Table beginning on
page 80 and before seasonal storage. When operating in heavy, wet
snow conditions, lubricate every 500 miles (800 km).
Lack of lubrication will adversely affect your ride and the life of the
suspension. For more information about suspension lubrication and
adjustments, see your POLARIS dealer.
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MAINTENANCE
Lubrication
Chaincase Oil
Check and change the chaincase oil at the intervals outlined in the
maintenance charts beginning on page 79. Maintain the oil level at the
top of the fill plug hole. POLARIS recommends the use of POLARIS
Synthetic Chaincase Lube. See page 122 for the part numbers of
POLARIS products.
Oil Level
Fill Plug
1. Position the vehicle on a level
surface.
2. Remove the fill plug.
3. Using a funnel, slowly add the
recommended oil until the fluid
begins to overflow.
4. Wipe the fill area with a clean
cloth.
5. Reinstall the fill plug. Torque to
6-10 ft. lbs. (8-13 Nm).
Oil Change
1. Position the vehicle on a level surface.
2. Place a drain pan under the drain plug. Remove the drain plug.
Allow the oil to drain completely.
3. Clean off all metal shavings from the plug.
TIP:The sealing surfaces on the drain plug and the oil tank should be clean and
free of burrs, nicks or scratches.
4. Reinstall the drain plug. Torque to 6-10 ft. lbs. (8-13 Nm).
5. Remove the fill plug. Clean off all metal shavings from the plug.
6. Using a funnel, slowly add the recommended oil until the fluid
begins to overflow. Fluid capacity is 9 oz. (266 ml).
7. Wipe the fill area with a clean cloth.
8. Reinstall the fill plug. Torque to 6-10 ft. lbs. (8-13 Nm).
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MAINTENANCE
Lubrication
Driveshaft Bearing (RMK/ASSAULT RMK)
Inject grease into the fitting on the
Fitting
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.
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MAINTENANCE
Intake Filters
The intake foam filters
limit snow ingestion into
the intake system. When
operating in loose powder
snow, check the foam
filters periodically to
remove any accumulation
of snow.
Intake
Filters
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 fuel filter at the
intervals outlined in the Periodic Maintenance Table beginning on page
80.
Contaminated or poor quality fuel will shorten the life of the fuel filter
and result in poor engine performance. Always store fuel in clean fuel
containers. If low fuel pressure or reduced engine performance occurs
between the recommended fuel filter service intervals, the filter may
need replacement. See your dealer.
Inspect the fuel lines regularly for signs of deterioration or damage.
Always check fuel line condition after periods of storage. Normal
deterioration from weather and fuel compounds may occur. Replace
worn or damaged fuel lines promptly.
NOTICE: Kinking the fuel lines or using a pliers or similar tools to remove fuel
lines may cause damage to the lines. If a fuel line has been damaged
or kinked, replace it promptly.
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MAINTENANCE
Spark Plugs
Spark Plug Recommendations
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.
Refer to the specifications section for the specific spark plug to be used
in your snowmobile.
Change the spark plugs at the intervals outlined in the Periodic
Maintenance Table beginning on page 79.
• Use recommended spark plugs with the proper gap.
• Use only resistor-type spark plugs.
• Torque spark plugs to 18-22 ft. lbs. (24-30 Nm).
• Always carry spare spark plugs.
NOTICE: Using non-recommended spark plugs can result in serious engine
damage. A spark plug with a heat range too high will always cause
engine damage if the engine is operated in conditions more severe
than intended for that plug. Always use the spark plugs recommended
for your snowmobile.
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MAINTENANCE
Spark Plugs
Spark Plug Inspection
Spark plug condition is indicative of engine operation. The spark plug
firing end condition should be read after the engine has been warmed up
and the vehicle has been driven at higher speeds. Immediately check the
spark plug for correct color.
CAUTION! A hot exhaust system and engine can cause burns. Wear
protective gloves when removing a spark plug for inspection.
1. Remove the left side panel.
2. Remove the spark plug cap.
3. Using the special wrench provided in the tool pouch, rotate the
spark plug counter-clockwise to remove.
4. Reverse the procedure for spark plug installation. Torque to
specification.
5. Reinstall the spark plug cap.
Spark Plug Condition
Normal Plug
The normal insulator tip is gray, tan or light brown. There 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.
TIP:The tip should not be white. A white insulator tip indicates overheating,
caused by use of an improper spark plug or incorrect carburetor/throttle
body adjustments.
Wet Fouled Plug
The wet fouled insulator tip is black. A damp oil film covers the firing
end. There may be a carbon layer over the entire nose. Generally, the
electrodes are not worn. General causes of fouling are excessive oil or
use of non-recommended injection oil.
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MAINTENANCE
Oil Lines
Inspect oil line condition every 1000 miles (1600 km) as outlined in the
maintenance charts beginning on page 79.
Oil Filter
Please see your dealer for replacement of the in-line oil filter every 2000
miles (3200 km) as outlined in the maintenance charts beginning on
page 79.
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MAINTENANCE
Cooling System
Coolant
The coolant supplied in the system at the factory is a 50/50 mixture of
ethylene-glycol and distilled water, which will provide adequate freeze
protection under most conditions. If the vehicle will be stored or
operated at extremely low temperatures, greater protection may be
required. Please see your POLARIS dealer.
When adding or changing coolant, POLARIS recommends using
POLARIS Antifreeze 60/40 Premix, which is already premixed and
ready to use. Do not dilute with water. Never exceed a 60% antifreeze/
40% water mixture. See page 122 for POLARIS products.
Never add tap water to the cooling system. Minerals cause deposits and
may react adversely with the metals in the engine and cooling system.
Coolant Level
The engine coolant level is controlled by the recovery system. The
recovery system components are:
• Coolant bottle/overflow tank
• Pressure cap
• Connecting hoses
Always maintain the coolant level at or
slightly above the FULL COLD mark on
the coolant bottle (when the engine is
cold).
“Full Cold” Mark
1. Stop the engine.
2. Open the right side panel.
3. View the coolant level in the coolant
bottle.
4. Add coolant as needed.
NOTICE: Operating the snowmobile with insufficient coolant will result in
overheating and serious engine damage. Always maintain the coolant
level as recommended.
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MAINTENANCE
Cooling System
Engine Overheating
The over-temperature indicator on the
instrument cluster will illuminate when the
engine is overheating. The indicator will
flash when engine temperature reaches
critical levels.
Illuminated Indicator
Take action to cool the engine:
• Drive in loose snow.
• View the coolant level. Do not open the
pressure cap while the engine is hot.
Add coolant if the level is low.
• Stop the engine and allow it to cool down.
If you must continue to operate while the indicator light is illuminated,
drive slowly and stop the engine frequently to allow it to cool down.
Flashing Indicator
If the indicator flashes, continued operation could result in serious
engine damage. The system will automatically reduce engine power and
create a misfire condition. Stop the engine immediately. Allow the
engine to cool down.
If engine overheating seems to be caused by something other than poor
cooling conditions, see your dealer for service.
Flushing the Cooling System
To ensure that the coolant maintains its ability to protect the engine,
drain the system completely every two years and add a fresh mixture of
antifreeze and distilled water. This service must be performed when the
engine is cold. Ask your POLARIS dealer to check the coolant when he
performs the fall tune-up on your snowmobile.
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MAINTENANCE
Cooling System
Bleeding the Cooling System
CAUTION! Steam and hot liquids will cause burns to your skin. Never bleed the
cooling system or remove the pressure cap when the engine is warm or hot.
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.
NOTICE: If coolant flow becomes restricted or plugged, coolant loss, air lock or
engine damage may result.
1. Position the vehicle so that the top of the tunnel is level. Elevate the
front of the vehicle slightly if necessary.
2. Make sure the engine is cold before continuing.
3. Remove the right side panel.
4. Fill the coolant bottle with properly mixed coolant to the maximum
mark. Do not install the pressure cap at this time.
5. Remove the bleed screw from the water outlet manifold and/or the
thermostat housing. Allow the coolant to bleed through the system
until it runs out the bleed holes. Reinstall the bleed screw into the
manifold.
6. Add coolant to the coolant bottle to the maximum mark.
7. Reinstall the side panel. Always ensure that the hood and side
panels are securely in place before starting the engine.
8. Start the engine and run at a fast idle for two to three minutes.
Loosen the bleed screw occasionally to purge any trapped air.
9. Stop the engine and check the coolant bottle level. Add coolant as
needed. Reinstall the side panel.
10. Carefully and briefly touch the top of the tunnel cooler under the
seat. If the system is bled properly, the cooler will be warm to the
touch. If not, repeat step 8. Lift the front of the snowmobile slightly
to assist in the bleeding.
11. Remove the side panel. Reinstall the pressure cap. Reinstall the side
panel.
12. Carefully lower the front end of the snowmobile.
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MAINTENANCE
Exhaust System
Check the exhaust system for wear or damage at approximately 2000
miles (3200 km). Always allow the engine and exhaust system to cool
completely before inspecting.
CAUTION! Hot exhaust system parts can cause burns. Allow adequate time for
the exhaust system to cool. Never perform this procedure with the engine
running.
1. Open the side panels and remove the hood. See page 83.
2. Inspect the muffler and pipes for cracks or damage.
3. Check for weak or missing retaining springs or damper/support
grommets.
4. Check for loose clamps on the pipe covers.
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MAINTENANCE
Drive Chain Tension (RMK/ASSAULT RMK)
Check drive chain tension weekly and before each long trip.
1. Remove the side panels.
2. Rotate the driven clutch
counter-clockwise to move all
chain slack to the tensioner
side. Lock the brake lever
lock, or have an assistant hold
the brake lever firmly.
3. Loosen the adjuster bolt jam
nut.
4. Finger tighten the adjuster bolt
until it can no longer be
adjusted by hand, then back
Jam
Adjuster
Bolt
off 1/4 turn.
Nut
5. Tighten the jam nut while
holding the adjuster bolt.
Torque to 21 ft. lbs. (28 Nm).
6. Reinstall the side panels.
7. Release the brake lever lock.
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MAINTENANCE
Brakes
Hydraulic Brake Inspection
Inspect the brake lever reserve before each use of the snowmobile. See
page 59.
Brake pads must be replaced when the brake pad material becomes
thinner than the backing plate (approximately 1/16 inch or 1.5 mm). A
kit is available for replacing brake pads. See your dealer.
WARNING! Brake failure during operation can result in serious injury or death.
Properly functioning brakes are vital to your safety. Be sure the brake pads do
not drag on the disc and that brake lever travel is not excessive. Always replace
brake pads when the brake pad material becomes thinner than the backing plate
(approximately 1/16 inch or 1.5 mm).
Brake Components
1. Brake Caliper
2. Brake Disc
1
4
3
3. Brake Pad Material (Replace
when thickness is less than
1/16 inch or 1.5 mm).
4. Anti-rattle springs (come
with brake pad kit)
Excessive Lever Travel
Hydraulic brakes are self-
adjusting, but if excessive brake
pad clearance develops, bring the
snowmobile to an authorized
POLARIS dealer for inspection
and adjustment.
2
TIP:The PRO RMK and RMK ASSAULT models are equipped with a lightweight
brake disc that has vent holes. These holes may cause a high-pitched
sound during operation.
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MAINTENANCE
Brakes
Brake Fluid
The brake fluid level can be seen through a plastic sight glass in the
brake reservoir. If the fluid is sufficient, the sight glass will be black. If
the sight glass is any color other than black, add brake fluid.
Replace brake fluid at least every two years with POLARIS DOT 4 high
temperature brake fluid. See page 122 for the part numbers of POLARIS
products.
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 fluid to drop, which can lead to early brake fade and
the possibility of accident or serious injury.
WARNING! 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.
NOTICE: Brake fluid will damage labels, paint and some plastics. Always wipe
up spills immediately.
97
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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 97.
8. Reinstall the gasket and cover.
98
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MAINTENANCE
Lights
When servicing a halogen lamp, avoid touching the lamp with bare
fingers. Oil from your skin leaves a residue, causing a hot spot that will
shorten the life of the lamp. If fingers do touch a lamp, clean it with
denatured alcohol.
Headlight Lamp Replacement
1. Peel back the foam shield covering the headlight assembly.
2. Remove the wire harness connector from the back of the headlight.
3. Grasp the bulb housing and turn it counter-clockwise to remove the
bulb.
4. Apply dielectric grease to the socket and install the new bulb.
Rotate the bulb 1/4 turn clockwise to secure it.
5. Reinstall the connector to the back of the headlight.
6. Secure the foam shield.
Taillight/Brake Light Replacement
The taillight assembly is not serviceable. If the light fails to operate
properly, replace the entire taillight assembly.
99
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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.
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.
100
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MAINTENANCE
Clutch System
Drive Belt Condition
Periodically check the condition and tension of the drive belt. 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.
Always carry a spare drive
belt. Store the spare belt in
the belt clip located under
the left side of the hood.
For improved drive-away during extremely cold temperatures, remove
the belt and warm it to room temperature. Reinstall it before starting the
snowmobile.
QUICKDRIVE Belt Condition (PRO RMK)
Periodically check the condition of
the QUICKDRIVE belt. Inspect the
belt for signs of excessive wear,
frayed edges, missing cogs and
cracks.
Replace the QUICKDRIVE belt
every 2000 miles (3200 km) and
whenever inspection reveals
excessive wear or damage. Special
tools are required to remove and
install the QUICKDRIVE belt. Please
see your POLARIS dealer for this
service, or refer to the instructions
provided with the purchase of a new
belt.
Improper track tension can result in
track ratcheting, which will affect
QUICKDRIVE belt durability.
Always maintain proper track tension.
See page 106.
101
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MAINTENANCE
Clutch System
Drive Belt Deflection
1
Measure belt deflection with both
clutches at rest and in their full
neutral position.
2
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. Loosen the 7/16-inch jam nut on the belt width adjuster.
2. Using a 1/8-inch Allen wrench, turn the set screw inward
(clockwise) to increase the distance between the sheaves or outward
(counter-clockwise) to decrease the distance.
3. Tighten the jam nut.
102
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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. Rotate the driven clutch counter-
clockwise 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.
2. Turn the ignition key off. Wait for the engine to come to a complete
stop.
3. Lock the parking brake.
4. Remove the left side panel.
5. Rotate the driven clutch counter-clockwise 1/4 turn by hand to
ensure forward engagement.
6. Locate the L-wrench in the tool kit. Install the wrench into the open
threaded hole in the outer sheave of the clutch.
7. 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.
8. Remove the belt from the driven clutch.
103
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MAINTENANCE
Clutch System
Drive Belt Installation
1. With the L-wrench inserted into
the threaded hole and the sheaves
in the open position, install the
drive belt.
TIP:Install the belt so that the numbers
can be read correctly on the left side
of the vehicle, or in the direction in
which the belt was originally
installed.
2. Wiggle the belt to remove slack
while removing the L-wrench.
3. Reinstall the side panel.
4. Break in the new belt. See page 67.
104
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MAINTENANCE
Track Maintenance
Track Inspection
WARNING! Broken track rods can cause a rotating track to come off the
snowmobile, which could cause serious injury or death. Never operate with a
damaged track. Never 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 to
check for damage.
3. Carefully examine the track
along the entire length of each
rod. Bend the track to check
for breakage.
4. Replace the track if any rod
damage is found.
Rod
Track Lubrication
The slide rail needs snow for lubrication. Excessive wear indicates
insufficient lubrication. A new rail slide can cause faster heat build-up
in limited lubrication, resulting in excessive wear.
WARNING! Operating with insufficient lubrication between the rail slide and
track guide clips can cause track failure, loss of vehicle control and loss of
braking ability, which can result in serious injury or death. Avoid operating for
extended periods on ice and other surfaces that have little or no snow for
lubrication.
If excessive rail slide wear occurs due to poor snow conditions,
additional wheel kits are available. See your dealer for more
information.
Track damage or failure caused by operation on ice or under other poor
lubrication conditions will void the track warranty.
105
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MAINTENANCE
Track Maintenance
WARNING! Moving parts can cut and crush body parts. When performing the
checks and adjustments recommended on the following pages, stay clear of all
moving parts. Never perform track measurement or adjustments with the engine
running.
Track Tension
Track adjustment is critical for proper handling. Always maintain
correct tension and alignment.
TRACK TENSION DATA CHART
Measurement
Suspension
Slack Measurement
Weight
Location
PRO-RIDE
RMK
3/8-1/2 inch (1.0-1.3 cm)
10 lbs.
(4.54 kg)
16 inches (40 cm)
ahead of rear
idler shaft
TIP:Tension adjustments should be made only after the track is warmed up and
limber.
1. Turn the engine off.
2. Lift the rear of the snowmobile and safely support it off the ground.
3. Place the recommended weight or downward pressure on the track
at the specified distance (see chart) ahead of the center of the rear
idler wheel.
4. Measure at the point where the weight is hanging.
106
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MAINTENANCE
Track Maintenance
Track Tension
5. Check for specified slack between the wear surface of the track clip
and the plastic slider. Refer to the Track Tension Data Chart on page
106.
If the track needs adjustment:
6. Loosen the rear idler shaft bolt.
7. Loosen the locknuts.
Adjusting Screw
Slack Measurement
Lock Nut
Shaft
Bolt
Track
16 inches
(40 cm)
10 lbs. (4.54 kg)
8. Tighten or loosen the track adjusting screws to provide equal
adjustment on both sides of the track.
9. Repeat the measurement on the other side of the track.
TIP:Check more frequently when the snowmobile is new.
10. Start the engine and slowly rotate the track at least five revolutions.
Let the track come to a stop (do not apply brakes).
11. Check track alignment (see page 108) and adjust as necessary.
12. Tighten the locknuts.
13. Tighten the idler shaft bolts.
14. Torque idler shaft bolts to 35 ft. lbs. (47.5 Nm).
107
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MAINTENANCE
Track Maintenance
Track Alignment
Periodically 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 snowmobile with the track off the
ground.
2. Start the engine and apply a small amount of throttle until the track
turns slowly at least five complete revolutions. Stop the engine and
let the track come to a stop (do not apply brakes).
3. Inspect track alignment by
looking through the track
window to make sure the
rails are evenly spaced on
each side. If the track runs
to the left, loosen the idler
shaft bolts, then loosen the
left locknut and tighten the
left adjusting bolt. If the
track runs to the right,
loosen the idler shaft bolts,
then loosen the right
locknut and tighten the
right adjusting bolt.
4. After adjustments are
Rail
complete, tighten the
locknuts and torque idler
shaft bolts to 35 ft. lbs.
(47.5 Nm).
5. Repeat steps 2 and 3 to verify proper alignment.
108
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MAINTENANCE
Steering System
Steering Inspection
Each week, or before a long ride, check all steering system fasteners and
tighten if necessary.
109
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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.
1. Place the handlebars in a straight-ahead position.
2. With only vehicle weight compressing the suspension, measure
10 inches (25.4 cm) forward from the center of the ski mounting
bolt. See illustration. At this point, measure between the skis. This is
measurement X.
3. Perform the same measurement rearward from the center of the ski
mounting bolt. This is measurement Y.
4. The X measurement should be 1/8-1/4 inch (3-6 mm) greater than
the Y measurement. If the skis are misaligned, see your dealer for
alignment correction as camber adjustment may also be affected.
X
10 in.
(25.4 cm)
10 in.
(25.4 cm)
Y
110
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MAINTENANCE
Steering System
Ski Skags
WARNING! Worn skis and/or skags will adversely affect handling. Loss of
vehicle control may result, causing serious injury or death. See your dealer's
studding chart for recommended skags. If you install longer or more aggressive
carbide skags than the original equipment, it may also be necessary to add track
studs to maintain proper vehicle control while turning on hard-packed snow or
ice.
Check skags before each use of the snowmobile to ensure positive
steering characteristics. Skags must be replaced when worn to half their
original diameter.
TIP:Carbide skags must be replaced if any abnormal wear or chipping is found.
Skag Replacement
1. Raise and support the front
of the snowmobile so the
skis are approximately 6
inches (15.2 cm) from the
ground.
2. Remove the attaching nuts
and pry the skag downward.
3. Remove the front end of the
Skag
skag.
4. Remove the rear end of the
skag.
5. Reverse the steps to install a
skag.
111
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MAINTENANCE
Steering System
Rail Slide Wear
For ease of inspection, all
POLARIS rail slides have
a wear limit indicator
Minimum
groove to indicate the
Thickness
minimum permissible slide
thickness. Replace the rail
slides if they are worn to
the top of the groove at any
point along their length.
Failure to do so may result
in permanent damage to
the track or rails.
Replace when
worn to top of
groove
112
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MAINTENANCE
Battery (if equipped)
WARNING! Improperly connecting or disconnecting battery cables can result in
an explosion and cause serious injury or death. When removing the battery,
always disconnect the negative (black) cable first. When reinstalling the battery,
always connect the negative (black) cable last.
Battery Removal
1. Remove the right side panel to access the battery. See page 83.
2. Disconnect the black (negative) battery cable first.
3. Disconnect the red (positive) battery cable last.
4. Remove the battery.
Battery Installation
When installing a new battery, make sure it's fully charged prior to its
initial use. Using a new battery that has not been fully charged can
damage the battery and result in a shorter life. It can also hinder vehicle
performance. Follow the battery charging instructions on page 115
before installing the battery.
1. Ensure that the battery is fully charged.
2. Set the battery in the battery holder.
3. Connect and tighten the red (positive) cable first.
4. Connect and tighten the black (negative) cable last.
5. Verify that cables are properly routed.
6. Reinstall the side panel.
113
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MAINTENANCE
Battery
Battery Storage
Whenever the vehicle is not used for a period of three months or more,
remove the battery from the vehicle, ensure that it's fully charged, and
store it out of the sun in a cool, dry place. Check battery voltage each
month during storage and recharge as needed to maintain a full charge.
Tip: Battery charge can be maintained by using a POLARIS Battery TenderTM
charger (PN 2871076) or by charging about once a month to make up for
normal self-discharge. Battery TenderTM can be left connected during the
storage period, and will automatically charge the battery if the voltage drops
below a pre-determined point.
Battery Charging
The following battery charging instructions apply only to the installa-
tion of a sealed battery. Read all instructions before proceeding with the
installation of this battery.
The sealed battery is already filled with electrolyte and has been sealed
and fully charged at the factory. Do not ever pry the sealing strip off or
add any other fluid to this battery.
The single most important thing about maintaining a sealed battery is to
keep it fully charged. Since the battery is sealed and the sealing strip
cannot be removed, you must use a voltmeter or multimeter to measure
DC voltage.
114
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MAINTENANCE
Battery
Battery Charging
For a refresh charge, follow all instructions carefully.
1. Check the battery voltage with a voltmeter or multimeter. A fully
charged battery will register 12.8 V or higher.
2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps
or less until the battery voltage is 12.8 or greater.
Tip: When using an automatic charger, refer to the charger manufacturer's
instructions for recharging. When using a constant current charger, use the
following guidelines for recharging.
WARNING! An overheated battery may explode, causing severe injury or
death. Always watch charging times carefully. Stop charging if the battery
becomes very warm to the touch. Allow it to cool before resuming charging.
Tip: Always verify battery condition before and 1-2 hours after the end of
charging.
Charge Time
State of
Charge
(Using constant current
Voltage
Action
charger @ standard amps
specified on top of battery)
100%
12.8-13.0 volts
None, check at 3
mos. from date of
manufacture
None required
75%-100%
12.5-12.8 volts
May need slight
charge, if no
3-6 hours
charge given,
check in 3 months
50%-75%
25%-50%
12.0-12.5 volts
11.5-12.0 volts
Needs charge
Needs charge
5-11 hours
At least 13 hours,
verify state of charge
0%-25%
11.5 volts or less Needs charge with
desulfating charger
At least 20 hours
115
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MAINTENANCE
Fall Tune-Up
For maximum performance, arrange for a fall service tune-up with your
POLARIS dealer. His experienced and trained service technician will
keep your snowmobile in peak operating condition.
Transporting the Snowmobile
Whenever the snowmobile is transported:
1. Be sure the fuel cap and oil cap are installed correctly.
2. Tie the snowmobile to the transporting unit securely using suitable
straps.
3. Remove the ignition key to prevent loss.
Extended Storage
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 122 for the part numbers of POLARIS
products.
Cleaning and Preservation
Proper storage starts with cleaning, washing, and waxing the hood, side
panels, chassis, and plastic parts. Wipe down remaining surfaces with a
damp cloth. Clean and touch up with paint any rusted or previously
painted surfaces. Be sure that corrosive salt and acids are removed from
surfaces before beginning preservation with waxes and rust inhibitors
(grease, oil or paint).
The snowmobile should be stored in a dry garage or shed, out of direct
sunlight, and covered with a fabric snowmobile cover. Plastic tarp may
cause condensation to form and damage snowmobile components.
116
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MAINTENANCE
Extended Storage
Controls and Linkage
Lubricate all bushings and cables as outlined in the Periodic
Maintenance Table beginning on page 80.
Clutch and Drive System
Remove the drive belt and store in a cool dry location. Do not lubricate
clutch components, except the driven clutch shaft bushing as outlined in
the Master Repair Manual. See your dealer.
Engine Protection
Proper preparation of the engine and fuel system is vital to the
prevention of rust and corrosion on precision engine parts during
storage. Whenever the snowmobile is stored for a period of more than
60 days, the engine must be fogged with fogging oil. Follow the engine
fogging instructions provided on the container.
Always add Carbon Clean or a fuel conditioner/stabilizer to the fuel
tank. Follow the instructions on the container, running the engine for
five minutes to get additives through the entire fuel system. Top off with
fresh fuel. Do not allow the snowmobile to run out of fuel.
Electrical Connections
Replace worn or frayed electrical wire and connectors. Be sure wiring
harness is properly secured away from sharp edges, steering linkage,
moving parts, and hot exhaust parts.
Track and Suspension
Moderate track tension should be maintained during summer storage.
The snowmobile should be supported off the ground to allow the track
to hang freely.
117
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SPECIFICATIONS
600 RMK / 600 PRO RMK
Capacities and Dimensions
Body Style
Rider Capacity
Coolant Capacity
PRO-RIDE
1
6 qts. (5.7 l) (RMK 144)
6.3 qts. (6.0 l) (RMK 155)
5.3 qts. (5.0 l) (PRO RMK 155)
Chaincase Oil Capacity
Fuel Tank Capacity
9 oz. (266.2 ml) (600 RMK)
N/A (600 PRO RMK)
11.5 gal. (43.5 l)
Gearcase Oil Capacity (oz./ml) N/A
Oil Capacity (qts./l)
Height
3 qts. (2.8 l)
51 inches (130 cm)
Length
125 inches (318 cm) (RMK 144)
129 inches (328 cm) (RMK 155 / PRO RMK 155)
Designed Width (in./cm)
Brake Type
Drive Clutch Center Distance
Drive Belt P/N
46.5 inches (118 cm)
Hayes Phantom/Phantom Lite
11.5 inches (29 cm)
3211115
Drive Clutch
P-85
Driven Clutch
Reverse Transmission
LW Team Roller Reverse
Electronic Reverse
Engine and Cooling
Engine
S4769-6044-OR6G (RMK)
S4770-6044-OR6G (PRO RMK)
Displacement
599 cc
Cylinders
2
Bore x Stroke (mm)
Alternator Output
Throttle Body
77.25 x 64
400 watt
Mikuni
Oil Injection
VES
Throttle Body Bore Size
Idle RPM
46 mm
1700 +/- 200
Rated Operating RPM
Cooling
8250 +/- 250
Liquid
Ignition Type
CDI
Ignition Timing
Spark Plug / Gap
Recommended Fuel Octane
18° @ idle 1700 RPM w/120°F (49°C) water temp
BPR 9ES /.027 inches (0.7 mm)
91 recommended, 87 minimum
118
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SPECIFICATIONS
600 RMK 144 / 600 RMK 155
Clutching Chart
ALTITUDE
Meters
(Feet)
Chaincase
Gearing/
Pitch
DriveClutch DriveClutch Driven Clutch
Driven
Helix
Shift Weight
Spring
Spring
*Shaded cells indicate factory settings.
LH BLK PUR
TEAM LW
(7043363)
(56/42/.36)
LW ER
(5135403)
0-450
(0-1500)
10-64
(1321585)
Black/Green
(7042083)
20:42
72 Pitch
LH BLK PUR
TEAM LW
(7043363)
(56/42/.36)
LW ER
(5135403)
450-900
(1500-3000)
10-62
(1321586)
Black/Green
(7042083)
20:42
72 Pitch
LH BLK PUR
TEAM LW
(7043363)
(56/42/.36)
LW ER
(5135403)
900-1500
(3000-5000)
10-60
(1321587)
Black/Green
(7042083)
20:42
72 Pitch
LH BLK PUR
TEAM LW
(7043363)
(56/42/.36)
LW ER
(5135403)
1500-2100
(5000-7000)
10-58
(1321588)
Black/Green
(7042083)
20:42
72 Pitch
LH BLK PUR
TEAM LW
(7043363)
(56/42/.36)
LW ER
(5135403)
2100-2700
(7000-9000)
10-56
(1321684)
Black/Green
(7042083)
20:42
72 Pitch
LH BLK PUR
TEAM LW
(7043363)
(56/42/.36)
LW ER
(5135403)
2700-3350
(9000-11000)
10-54
(1321685)
Black/Green
(7042083)
20:42
72 Pitch
600 PRO RMK 155
Clutching Chart
ALTITUDE
Meters
(Feet)
QUICKDRIVE
Gearing/
Pitch
DriveClutch DriveClutch Driven Clutch
Driven
Helix
Shift Weight
Spring
Spring
*Shaded cells indicate factory settings.
LH BLK PUR
TEAM LW
(7043363)
(56/42/.36)
LW ER
(5135403)
0-450
(0-1500)
10-64
(1321585)
Black/Green
(7042083)
21:44
68 Pitch
LH BLK PUR
TEAM LW
(7043363)
(56/42/.36)
LW ER
(5135403)
450-900
(1500-3000)
10-62
(1321586)
Black/Green
(7042083)
21:44
68 Pitch
LH BLK PUR
TEAM LW
(7043363)
(56/42/.36)
LW ER
(5135403)
900-1500
(3000-5000)
10-60
(1321587)
Black/Green
(7042083)
21:44
68 Pitch
LH BLK PUR
TEAM LW
(7043363)
(56/42/.36)
LW ER
(5135403)
1500-2100
(5000-7000)
10-58
(1321588)
Black/Green
(7042083)
21:44
68 Pitch
LH BLK PUR
TEAM LW
(7043363)
(56/42/.36)
LW ER
(5135403)
2100-2700
(7000-9000)
10-56
(1321684)
Black/Green
(7042083)
21:44
68 Pitch
LH BLK PUR
TEAM LW
(7043363)
(56/42/.36)
LW ER
(5135403)
2700-3350
(9000-11000)
10-54
(1321685)
Black/Green
(7042083)
21:44
68 Pitch
119
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SPECIFICATIONS
800 RMK / 800 PRO RMK / 800 RMK ASSAULT
Capacities and Dimensions
Body Style
Rider Capacity
Coolant Capacity
PRO-RIDE
1
6.3 qts. (6.0 l) (RMK 155)
5.3 qts. (5.0 l) (PRO RMK 155)
5.3 qts. (5.0 l) (RMK ASSAULT 155)
5.5 qts. (5.2 l) (PRO RMK 163)
Chaincase Oil Capacity
Fuel Tank Capacity
9 oz. (266.2 ml) (RMK/RMK ASSAULT)
N/A (PRO RMK)
11.5 gal. (43.5 l)
Gearcase Oil Capacity (oz./ml) N/A
Oil Capacity (qts./l)
Height
3 qts. (2.8 l)
51 inches (130 cm)
Length
134 inches (340 cm) (PRO RMK 163)
129 inches (328 cm) (All Other)
Designed Width (in./cm)
48 inches (122 cm) (RMK ASSAULT)
46.5 inches (118 cm) (All Other)
Brake Type
Drive Clutch Center Distance
Drive Belt P/N
Hayes Phantom Lite
11.5 inches (29 cm)
3211115
Drive Clutch
P-85
Driven Clutch
Reverse Transmission
LW Team Roller Reverse
Electronic Reverse
Engine and Cooling
Engine
S4775-8044-OR8G (RMK 155)
S4773-8044-OR8G (All Other)
Displacement
794 cc
Cylinders
Monoblock
Bore x Stroke (mm)
Alternator Output
Throttle Body
85 x 70
400 watt
Mikuni
Oil Injection
VES
Throttle Body Bore Size
Idle RPM
48 mm
1700 +/- 200
Rated Operating RPM
Cooling
8250 +/- 250
Liquid
Ignition Type
CDI
Ignition Timing
Spark Plug / Gap
Recommended Fuel Octane
18° @ idle 1700 RPM w/120°F (49°C) water temp
BPR 9ES /.027 inches (0.7 mm)
91 recommended, 87 minimum
120
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SPECIFICATIONS
800 RMK 155 / 800 RMK ASSAULT 155
Clutching Chart
ALTITUDE
Meters
(Feet)
Chaincase
Gearing/
Pitch
Drive Clutch Drive Clutch Driven Clutch
Driven
Helix
Shift Weight
Spring
Spring
*Shaded cells indicate factory settings.
(56/42/.36)
LW ER
(5135403)
0-600
(0-2000)
10-68
(1322427)
140/330
(7043829)
LH BLACK Team
(7043063)
20:42
72 Pitch
(56/42/.36)
LW ER
(5135403)
600-1200
(2000-4000)
10-66
(1321584)
140/330
(7043829)
LH BLACK Team
(7043063)
20:42
72 Pitch
(56/42/.36)
LW ER
(5135403)
1200-1800
(4000-6000
10-64
(1321585)
140/330
(7043829)
LH BLACK Team
(7043063)
20:42
72 Pitch
(56/42/.36)
LW ER
(5135403)
1800-2400
(6000-8000)
10-62
(1321586)
140/330
(7043829)
LH BLACK Team
(7043063)
20:42
72 Pitch
LH BLK/PUR
TEAM LW
(7043363)
(56/42/.36)
LW ER
(5135403)
2400-3000
(8000-10000)
10-60
(1321587)
140/330
(7043829)
20:42
72 Pitch
LH BLK/PUR
TEAM LW
(7043363)
(56/42/.36)
LW ER
(5135403)
3000-3600
(10000-12000)
10-58
(1321588)
140/330
(7043829)
20:42
72 Pitch
800 PRO RMK
Clutching Chart
ALTITUDE
Meters
(Feet)
QUICKDRIVE
Gearing/
Pitch
Drive Clutch Drive Clutch Driven Clutch
Driven
Helix
Shift Weight
Spring
Spring
*Shaded cells indicate factory settings.
(56/42/.36)
LW ER
(5135403)
0-600
(0-2000)
10-68
(1322427)
140/330
(7043829)
LH BLACK Team
(7043063)
21:44
68 Pitch
(56/42/.36)
LW ER
(5135403)
600-1200
(2000-4000)
10-66
(1321584)
140/330
(7043829)
LH BLACK Team
(7043063)
21:44
68 Pitch
(56/42/.36)
LW ER
(5135403)
1200-1800
(4000-6000
10-64
(1321585)
140/330
(7043829)
LH BLACK Team
(7043063)
21:44
68 Pitch
(56/42/.36)
LW ER
(5135403)
1800-2400
(6000-8000)
10-62
(1321586)
140/330
(7043829)
LH BLACK Team
(7043063)
21:44
68 Pitch
LH BLK/PUR
TEAM LW
(7043363)
(56/42/.36)
LW ER
(5135403)
2400-3000
(8000-10000)
10-60
(1321587)
140/330
(7043829)
21:44
68 Pitch
LH BLK/PUR
TEAM LW
(7043363)
(56/42/.36)
LW ER
(5135403)
3000-3600
(10000-12000)
10-58
(1321588)
140/330
(7043829)
21:44
68 Pitch
121
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POLARIS PRODUCTS
Part No.
Description
Engine Lubricants
Fogging Oil (12 oz. Aerosol)
2870791
2875035
2875036
2877882
2877953
2877883
2877884
Premium Blue 2-Cycle Oil (qt./.95 l) (break-in only)
Premium Blue 2-Cycle Oil (gal./3.8 l) (break-in only)
VES 2-Cycle Oil (qt./.95 l)
VES 2-Cycle Engine Oil (2 qt./1.9 l)
VES 2-Cycle Engine Oil (gal./3.8 l)
VES 2-Cycle Engine Oil (2.5 gal./9.5 l)
Chaincase Lubricants
2873105
2873106
SCL - Synthetic Chaincase Lubricant (qt./.95 l)
SCL - Synthetic Chaincase Lubricant (gal./3.8 l)
Grease/Specialized Lubricants
Grease Gun Kit, All Season (3 oz./89 ml)
All Season Grease (3 oz./89 ml cartridge)
All Season Grease (14 oz./414 ml cartridge)
Dielectric Grease (Nyogel™)
2871312
2871322
2871423
2871329
Coolant
2871534
2871323
Polaris Antifreeze 60/40 Premix (qt./.95 l)
Polaris Antifreeze 60/40 Premix (gal./3.8 l)
Additives/Miscellaneous
2871326
2870652
2872189
2872893
2870505
2872889
2872890
2878018
Carbon Clean
Fuel Stabilizer
DOT4 Brake Fluid
Engine Degreaser
Isopropyl Fuel De-Icer
Brake and Clutch Cleaner
Carb and Throttle Body Cleaner
Shock Thread Spray Lubricant
122
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TROUBLESHOOTING
Engine Troubleshooting
Problem
Probable Cause Solution
Erratic engine RPM Drive clutch binding • SEE YOUR DEALER.
during acceleration
or load variations
Driven clutch
malfunction
• SEE YOUR DEALER.
Engine doesn't turn
Seized engine
• SEE YOUR DEALER. Seizure is a
result of poor lubrication,
inadequate fuel supply, broken parts
or improper cooling.
Hydrostatic lock
• Fuel may have entered the crankcase
while the vehicle was standing or
being transported. SEE YOUR
DEALER to correct the cause. Drain
plug(s) are located on the lower
crankcase for emergency draining.
Engine turns but fails Faulty ignition
to start
• Install new spark plug(s). If engine
still fails to start, check for spark. If
there's no spark, SEE YOUR
DEALER.
No fuel to engine
• Make sure the fuel valve is on.
• Make sure tank contains fuel.
• Ice may be in the fuel line, filter or
pump. Add isopropyl alcohol to the
fuel system.
• SEE YOUR DEALER.
Poor engine
compression
• This indicates a major engine
problem that must be repaired before
operating. SEE YOUR DEALER.
Engine lacks power
Fouled or defective
spark plug(s)
• Replace the plug(s).
Fuel filter (loss of
high RPM power)
• SEE YOUR DEALER.
Plugged fuel filter or • SEE YOUR DEALER.
tank pick-up sock
Incorrect clutching
Faulty plug(s)
Fuel System
• SEE YOUR DEALER.
• Change plug(s).
Engine continually
backfires
• Dirt or ice may be in the fuel system
(deicer should be added to non-
ethanol fuel at all times for
assurance against fuel line icing).
Incorrect throttle
freeplay or faulty
switch
• SEE YOUR DEALER.
Engine requires
more than normal
pulls to start
Poor fuel
Not enough fuel
getting to engine
• Replace with fresh winter fuel.
• SEE YOUR DEALER.
Plugged fuel filter or • SEE YOUR DEALER.
tank pick-up sock
123
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TROUBLESHOOTING
Drive System Troubleshooting
Problem
Probable Cause Solution
Machine fails to
move
Clutch jammed
• Check for twisted belt or broken
spring. SEE YOUR DEALER.
Track jammed
• Foreign object may be caught or the
rail slide melted to the track clips
due to lack of lubrication.
• Track may be iced up or frozen to
the ground.
Chaincase sprocket
or chain jammed or
broken
• Chain is loose or broken or chain
tightener is loose. SEE YOUR
DEALER.
Sheared teeth on
• Replace QUICKDRIVE belt.
• Replace QUICKDRIVE belt.
• Replace QUICKDRIVE belt.
• Inspect and replace as needed.
QUICKDRIVE belt
Broken
QUICKDRIVE belt
Ratcheting or jerky
drive-away from
slow speed
Sheared teeth on
QUICKDRIVE belt
Drive belt surface
flat spots
Noise in drive
system
Broken drive clutch • SEE YOUR DEALER.
components
Bearing failure/
chaincase, jackshaft,
or front drive shaft
• SEE YOUR DEALER.
Drive belt surface
flat spots
• Inspect and replace as needed.
Drive chain loose or • Inspect and adjust, or replace.
worn, sprocket teeth
broken
SEE YOUR DEALER.
Sheared teeth on
QUICKDRIVE belt
• Replace QUICKDRIVE belt.
Harsh drive clutch
engagement
Worn or narrow belt • Replace the drive belt.
Excessive belt/
• SEE YOUR DEALER.
sheave clearance
Drive belt turns over Wrong belt
• Replace the drive belt.
Clutch alignment out • SEE YOUR DEALER.
of spec
Engine mount
broken or loose
• Inspect and replace. SEE YOUR
DEALER.
124
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TROUBLESHOOTING
Drive Belt Troubleshooting
Belt Wear/Burn Diagnosis
Causes
Solutions
Driving at low RPM
• Drive at higher RPMs. Gear the machine down. Check
belt deflection.
Insufficient warm-up
Towing at low RPM
• Warm the engine at least five minutes. Take the drive
belt off the snowmobile in extremely cold weather and
warm it up. Break snowmobile loose from the snow.
• Do not tow in deep snow. Use fast, aggressive throttle
to engage clutch.
Riding with high RPM
and slow speed (8000
RPM/10 MPH/16 km/h)
• Lower the gear ratio. Reduce RPM. Avoid riding in
high ambient temperatures. Check for snow ingestion.
Ice and snow build-up
between track and tunnel
• Warm the engine at least five minutes. Take the drive
belt off the snowmobile in extremely cold weather and
warm it up. Break snowmobile loose from the snow.
Poor engine performance • Check for fouled plugs and water, ice or dirt in the fuel
tank or fuel line.
Loading snowmobiles
onto trailers
• Skis may gouge into trailers and prevent the drivetrain
from spinning properly. Use enough speed to drive the
snowmobile completely onto the trailer. Push and pull
it to finish loading if necessary.
Clutch malfunction
• Inspect clutch components. See your dealer.
• Use fast, aggressive throttle to engage clutch.
Slow, easy clutch
engagement
125
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TROUBLESHOOTING
Suspension Troubleshooting
Problem
Solution
Rear suspension
bottoms too easily
• Refer to the suspension adjustment and set-up information
beginning on page 50.
• Revalve rear track shock (see your dealer).
Rides too stiff in rear • Refer to the suspension adjustment and set-up information
beginning on page 50.
• Check for binding suspension shafts and grease all pivot
points.
Too much weight
transfer when
climbing
• Refer to the suspension adjustment and set-up information
beginning on page 50.
Too little weight
transfer when
climbing
• Refer to the suspension adjustment and set-up information
beginning on page 50.
Machine darts from
side to side
• Check ski alignment (see page 110).
• Make sure spindles and all steering components turn freely.
• Check for excessive play in steering assembly (see your
dealer).
• Ensure skags are straight on skis.
Front end pushes
Steering is heavy
• Check for worn skags.
• Check for binding front suspension shafts and steering
components, grease all pivot points (elevate front of
snowmobile).
• Increase IFS preload (if equipped) (see page 54).
• Make sure spindles and all steering components turn freely.
• Check ski alignment (see page 110).
• Check skags and skis for damage.
126
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WARRANTY
Service and Warranty Information
Obtaining Service and Warranty Assistance
Read and understand the service data and the POLARIS warranty information
contained in this manual. Contact your POLARIS dealer for replacement parts,
service or warranty. Your dealer receives frequent updates on changes,
modifications and tips on snowmobile maintenance, which may supercede
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
2. Model number
3. Dealer name
5. Details of trouble experienced
6. Length of time and conditions of operation
7. Previous correspondence
4. Date of purchase
Use the page provided near the front of your Owner's Manual to record the
identification numbers of your snowmobile and its engine.
POLARIS Customer Service
United States: 1-888-704-5290
Canada: 1-204-925-7100
127
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WARRANTY
Limited Warranty
POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR
LIMITED WARRANTY on all components of the POLARIS snowmobile against
defects in material or workmanship. Warranty period will vary regionally. This warranty
covers the parts and labor charges for repair or replacement of defective parts that are
covered by this warranty. The warranty begins on the date of purchase. This warranty is
transferable to another consumer, during the warranty period, through a POLARIS
dealer.
Registration
At the time of sale, the Warranty Registration Form must be completed by your dealer
and submitted to POLARIS within ten days. Upon receipt of this registration, POLARIS
will record the registration for warranty. No verification of registration will be sent to
the purchaser as the copy of the Warranty Registration Form will be the warranty
entitlement. If you have not signed the original registration and received the customer
copy, please contact your dealer immediately. NO WARRANTY COVERAGE WILL
BE ALLOWED UNLESS THE SNOWMOBILE IS REGISTERED WITH POLARIS.
Initial dealer preparation and setup of your snowmobile is very important in ensuring
trouble-free operation. Purchasing a snowmobile in the crate or without proper dealer
setup will void your warranty coverage.
Warranty Coverage and Exclusions
Limitations of warranties and remedies
This warranty excludes any failures not caused by a defect in material or workmanship.
The warranty does not cover accidental damage, normal wear and tear, abuse or
improper handling. The warranty also does not cover any snowmobile that has been
structurally altered, neglected, improperly maintained, used for racing or used for
purposes other than for which it was manufactured. The warranty does not cover 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 paint or finish, stress cracks,
tearing or puncturing of upholstery material, corrosion or defects in parts, components
or the snowmobile due to fire, explosions or any other cause beyond POLARIS' control.
This warranty does not cover the use of unauthorized lubricants, chemicals, or fuels that
are not compatible with the snowmobile.
The exclusive remedy for breach of this warranty shall be, at POLARIS' exclusive
option, repair or replacement of any defective materials, or components or products.
THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES
AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS
SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL,
CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION,
WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY
OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE. THIS
EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND SPECIAL DAMAGES
IS INDEPENDENT FROM AND SHALL SURVIVE ANY FINDING THAT THE
EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL PURPOSE. Some states do not
permit the exclusion or limitation of incidental or consequential damages or implied
warranties, so the above limitations or exclusions may not apply to you if inconsistent
with controlling state law.
128
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WARRANTY
Limitations of warranties and remedies
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE ABOVE ONE
YEAR WARRANTY PERIOD. POLARIS FURTHER DISCLAIMS ALL EXPRESS
WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow
limitations on how long an implied warranty lasts, so the above limitation may not apply
to you if inconsistent with controlling state law.
Promotional Warranties
Promotional warranties are sometimes offered by POLARIS. These warranties can be,
but are not limited to:
•
•
•
Two-year extended engine coverage
Two-year powertrain coverage
Extended service contract
If you selected any type of extended warranty coverage as part of a POLARIS retail
program, please contact any authorized POLARIS dealer for additional information.
How to Obtain Warranty Service
If your snowmobile requires warranty service, you must take it to a POLARIS dealer
authorized to repair POLARIS snowmobiles. When requesting warranty service you
must present your copy of the Warranty Registration form to the dealer. (The cost of
transportation to and from the 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 additional assistance is needed.
This warranty gives you specific legal rights, and you may also have other rights which
vary from state to state.
If any of the above terms are void because of state or federal law, all other warranty
terms will remain in effect.
Engine Oil
1. Mixing oil brands or using non-recommended oil may cause engine damage. We
recommend the use of POLARIS engine oil.
2. Damage resulting from the use of non-recommended lubricants may not be covered
by warranty.
129
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WARRANTY
Conditions and Exclusions
In order to qualify for warranty, the product must have been properly set up and tested
by a POLARIS Dealer (if applicable). Failure of any dealer to perform the required
vehicle Pre-Delivery Inspection, perform all applicable service bulletins and have the
consumer sign the PDI form prior to delivery may void the warranty. Failure to provide
proof of required periodic maintenance upon request may result in denial of warranty
coverage. Use of the recommended POLARIS products for lubrication and maintenance
as directed by the Owner's manual is highly recommended. Should a failure occur
during the warranty period resulting from the use of non-recommended products,
warranty coverage may be denied.
Warranty does not apply to parts exposed to friction surfaces, stresses, environmental
conditions and/or contamination. The following items are excluded from warranty
consideration if the failure was due to wear or not the direct result of a defect:
Skis
Ski wear rods
Tracks
Slide rails
Suspension components
Brake components
Seat components
Clutches and components
Steering components
Batteries
Finished and unfinished surfaces
Carburetor/Throttle body components
Engine components
Drive belts
Hydraulic components
Circuit breakers/Fuses
Electronic components
Light bulbs/Sealed beam lamps
Idler wheels
Warranty applies to the product only and does not allow for coverage of personal loss.
Some items are considered "consumable," meaning they are considered part of normal
maintenance or part of completing an effective repair. The following items are excluded
from warranty coverage in the event of a warranty claim:
Spark Plugs
Filters
Fuel
Lubricants such as oil, grease, etc.
Batteries (unless defective)
Cosmetic damage/repair
Coolants
Sealants
Hotel fees
Meals
Towing charges
Mileage
Rentals/Loss of product use
Shipping/ handling fees
Product pick-up/delivery
Loss of vacation/personal time
This warranty also excludes failures resulting from improper lubrication; improper
engine timing; improper fuel; surface imperfections caused by external stress, heat, cold
or contamination; operator error or abuse; improper component alignment, tension,
adjustment or altitude compensation; failure due to snow, water, dirt or other foreign
substance ingestion/contamination; improper maintenance; modified components; use
of aftermarket components resulting in failure; unauthorized repairs; repairs made after
the warranty period expires or by an unauthorized repair center; use of the product in
competition or for commercial purposes. Warranty will not apply to any product which
has been damaged by abuse, accident, fire or any other casualty not determined a defect
of materials or workmanship.
130
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WARRANTY
Exported Vehicles
EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO
WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS
SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED
LOCATION.
This policy does not apply to vehicles that have received authorization for export from
POLARIS Industries. Dealers may not give authorization for export. You should consult
an authorized dealer to determine this vehicle's warranty or service bulletin coverage if
you have any questions.
This policy does not apply to vehicles registered to government officials or military
personnel on assignment outside the country of the selling dealer's authorized location.
This policy does not apply to Safety Bulletins.
How to Get Service
In the Country where your vehicle was purchased:
Warranty or Service Bulletin repairs 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 was purchased:
If you are traveling temporarily outside the country where your vehicle was purchased,
you should take your vehicle to an authorized POLARIS dealer. You must show the
dealer photo identification from the country of the selling dealer's authorized location as
proof of residence. Upon residence verification, the servicing dealer will be authorized
to perform the warranty repair.
If You Move:
If you move to another country, be sure to contact POLARIS Customer Assistance and
the customs department of the destination country before you move. Vehicles
importation rules vary considerably from country to country. You may be required to
present documentation of your move to POLARIS Industries in order to continue your
warranty coverage. You may also be required to obtain documentation from POLARIS
Industries in order to register your vehicle in your new country. You should warranty
register your vehicle at a local POLARIS dealer in your new country immediately after
you move to continue your warranty coverage and to ensure that you receive safety
information and notices regarding your vehicle.
131
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WARRANTY
How to Get Service
If Purchased From A Private Party:
If you purchase a POLARIS product from a private citizen outside of the country in
which the vehicle was originally purchased, all warranty coverage will be denied. You
must nonetheless warranty register your vehicle under your name and address with a
local POLARIS dealer in your country to ensure that you receive safety information and
notices regarding your vehicle.
Notice
If your vehicle is registered outside of the country where it was purchased, and you have
not followed the procedure set out above, your vehicle will no longer be eligible for
warranty or service bulletin coverage of any kind, other than safety bulletins. (Vehicles
registered to Government officials or military personnel on assignment outside of the
country where the vehicle was purchased will continue to be covered by the basic
warranty.)
For questions call POLARIS Customer Assistance (see page 127).
132
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WARRANTY
U.S.A. EPA Emissions Limited Warranty
This emissions limited warranty is in addition to the POLARIS standard limited
warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first
purchased, this emissions-certified vehicle is designed, built and equipped so it
conforms with applicable U.S. Environmental Protection Agency emission regulations.
POLARIS warrants that the vehicle is free from defects in materials and workmanship
that would cause it to fail to meet these regulations.
The warranty period for this emissions-certified vehicle starts on the date the vehicle is
first purchased and continues for a period of 200 hours of engine operation, 4000
kilometers (2485 miles) of vehicle travel, or 30 calendar months from the date of
purchase, whichever comes first.
This emissions limited warranty covers components whose failure increases the
vehicle’s regulated emissions, and it covers components of systems whose only purpose
is to control emissions. Repairing or replacing other components not covered by this
warranty is the responsibility of the vehicle owner. This emissions limited warranty does
not cover components whose failure does not increase the vehicle’s regulated emissions.
For exhaust emissions, emission-related components include any engine parts related to
the following systems:
•
•
Air-induction system
Fuel system
•
•
Ignition system
Exhaust gas recirculation systems
The following parts are also considered emission-related components for exhaust
emissions:
•
•
Aftertreatment devices
Crankcase ventilation valves
•
•
Sensors
Electronic control units
The following parts are considered emission-related components for evaporative
emissions:
•
•
•
•
•
•
•
•
•
Fuel Tank
Fuel Cap
Fuel Line
Fuel Line Fittings
Clamps*
Pressure Relief Valves*
Control Valves*
Control Solenoids*
Electronic Controls*
•
•
•
•
•
•
•
•
•
Vacuum Control Diaphragms*
Control Cables*
Control Linkages*
Purge Valves
Vapor Hoses
Liquid/Vapor Separator
Carbon Canister
Canister Mounting Brackets
Carburetor Purge Port Connector
*As related to the evaporative emission control system.
133
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WARRANTY
U.S.A. EPA Emissions Limited Warranty
The exclusive remedy for breach of this limited warranty shall be, at the exclusive
option of POLARIS, repair or replacement of any defective materials, components or
products. THE REMEDIES SET FORTH IN THIS LIMITED WARRANTY ARE THE
ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS
WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR
INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY
DESCRIPTION,WHETHER ARISING OUT OF EXPRESS OR IMPLIED
WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE OR OTHER TORT OR
OTHERWISE. THIS EXCLUSION OF CONSEQUENTIAL, INCIDENTAL, AND
SPECIAL DAMAGES IS INDEPENDENT FROM AND SHALL SURVIVE ANY
FINDING THAT THE EXCLUSIVE REMEDY FAILED OF ITS ESSENTIAL
PURPOSE.
ALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO ANY
IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A
PARTICULAR PURPOSE) ARE LIMITED IN DURATION TO THE WARRANTY
PERIOD DESCRIBED HEREIN. POLARIS DISCLAIMS ALL EXPRESS
WARRANTIES NOT STATED IN THIS WARRANTY. Some states do not allow
limitations on how long an implied warranty lasts, so the above limitation may not apply
if it is inconsistent with the controlling state law.
This limited warranty excludes failures not caused by a defect in material or
workmanship.This limited warranty does not cover damage due to accidents, abuse or
improper handling, maintenance or use. This limited warranty also does not cover any
engine that has been structurally altered, or when the vehicle has been used in racing
competition. This limited warranty also does not cover physical damage, corrosion or
defects caused by fire, explosions or other similar causes beyond the control of
POLARIS.
Owners are responsible for performing the scheduled maintenance identified in the
owner's manual. POLARIS may deny warranty claims for failures that have been caused
by the owner’s or operator’s improper maintenance or use, by accidents for which
POLARIS has no responsibility, or by acts of God.
Any qualified repair shop or person may maintain, replace, or repair the emission
control devices or systems on your vehicle. POLARIS recommends that you contact an
authorized POLARIS dealer to perform any service that may be necessary for your
vehicle. POLARIS also recommends that you use only Pure POLARIS parts. It is a
potential violation of the Clean Air Act if a part supplied by an aftermarket parts
manufacturer reduces the effectiveness of the vehicle's emission controls. Tampering
with emission controls is prohibited by federal law.
If you have any questions regarding your warranty rights and responsibilities, please
contact the POLARIS Warranty Department at 1-888-704-5290.
134
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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)
500 mi.
(800 km)
1000 mi.
(1600 km)
2000 mi.
(3200 km)
135
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MAINTENANCE LOG
DATE
MILES
(KM)
TECHNICIAN
SERVICE PERFORMED / COMMENTS
136
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INDEX
A
D
Accessories . . . . . . . . . . . . . . . . . . . . 30
Air Pollution . . . . . . . . . . . . . . . . . . . . 6
Avalanches . . . . . . . . . . . . . . . . . . . . 15
DET. . . . . . . . . . . . . . . . . . . . . . . 32-33
Detonation Elimination Technology 32-
33
Diagnostic Display Codes. . . . . . 48-49
Diagnostic Display Mode . . . . . . . . . 47
Disabled Operators . . . . . . . . . . . . . . 12
Display, Standard/Metric . . . . . . . . . 40
Drive Belt
Adjustment. . . . . . . . . . . . . . . . . 102
Belt Safety . . . . . . . . . . . . . . . . . . 18
Break-In . . . . . . . . . . . . . . . . . . . . 67
Break-In, QUICKDRIVE . . . . . . 67
Condition . . . . . . . . . . . . . . . . . . 101
Condition, QUICKDRIVE. . . . . 101
Installation . . . . . . . . . . . . . . . . . 104
QUICKDRIVE Belt/Handling. . . 29
Removal . . . . . . . . . . . . . . . . . . . 103
Drive Belt Deflection . . . . . . . . . . . 102
Drive Chain Tension . . . . . . . . . . . . 95
Driver Awareness . . . . . . . . . . . . . . . 14
Driveshaft Bearing Lubrication . . . . 86
Driving Downhill . . . . . . . . . . . . . . . 17
Driving in Hilly Terrain . . . . . . . . . . 17
Driving on Slippery Surfaces . . . . . . 16
Driving Responsibly . . . . . . . . . . . . . 19
B
Battery . . . . . . . . . . . . . . . . . . 113-115
Charging. . . . . . . . . . . . . . . 114-115
Installation . . . . . . . . . . . . . . . . . 113
Removal . . . . . . . . . . . . . . . . . . . 113
Storage . . . . . . . . . . . . . . . . . . . . 114
Belt Handling, QUICKDRIVE. . . . . 29
Brake Lever Travel Inspection . . . . . 59
Brakelight Replacement . . . . . . . . . . 99
Brakes . . . . . . . . . . . . . . . . . 59, 96-98
Brake Fluid. . . . . . . . . . . . . . . . . . 97
Components . . . . . . . . . . . . . . . . . 96
Inspection. . . . . . . . . . . . . . . . . . . 96
Lever Travel. . . . . . . . . . . . . . . . . 96
System Bleeding . . . . . . . . . . . . . 98
Break-In Period. . . . . . . . . . . . . . 65-67
C
Chaincase Oil . . . . . . . . . . . . . . . . . . 85
Cleaning/Preservation for Storage . 116
Clutch Alignment Offset. . . . . . . . . 100
Clutch Safety. . . . . . . . . . . . . . . . . . . 18
Clutch System. . . . . . . . . . . . . 100-104
Clutch Warning. . . . . . . . . . . . . . . . . 21
Clutch/Drive System Care for Storage .
117
E
Electrical Connections Care for Storage
117
Emission Control Information . . . . . 78
Emissions Limited Warranty . 133-134
Engine Break-In . . . . . . . . . . . . . 65-66
Engine Overheating . . . . . . . . . . . . . 92
Engine Protection for Storage. . . . . 117
Engine Restarting . . . . . . . . . . . . . . . 64
Engine Safety . . . . . . . . . . . . . . . . . . 10
Engine Starting . . . . . . . . . . . . . . 63-64
Engine Stop Switch. . . . . . . . . . . . . . 72
Environment Preservation . . . . . . . . . 6
Exhaust System. . . . . . . . . . . . . . . . . 94
Clutching Charts
600 RMK/600 PRO RMK . . . . . 119
800 RMK/800 PRO RMK/800 RMK
ASSAULT . . . . . . . . . . . . . . . . . 121
Cold Weather Drive-Away . . . . . . . . 18
Controls and Linkage Care for Storage
117
Coolant . . . . . . . . . . . . . . . . . . . . . . . 91
Coolant Level . . . . . . . . . . . . . . . . . . 91
Cooling System. . . . . . . . . . . . . . 91-93
Cooling System, Bleeding . . . . . . . . 93
Cooling System, Flushing. . . . . . . . . 92
Customer Service . . . . . . . . . . . . . . 127
137
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INDEX
F
L
Fasteners, Hood and Side Panel. . . . 61
Lights . . . . . . . . . . . . . . . . . . . . . . . . 99
Headlight Replacement. . . . . . . . . 99
Taillight/Brake Light . . . . . . . . . . 99
Lubrication. . . . . . . . . . . . . . . . . 84-86
Rear Suspension . . . . . . . . . . . . . . 84
Fluid Change
Chaincase . . . . . . . . . . . . . . . . . . 85
Coolant . . . . . . . . . . . . . . . . . . . . 92
Fluid Level
Brake Fluid . . . . . . . . . . . . . . . . . 97
Chaincase . . . . . . . . . . . . . . . . . . 85
Coolant . . . . . . . . . . . . . . . . . . . . 91
Fuel . . . . . . . . . . . . . . . . . . . . . . . . . 69
Fuel Filter. . . . . . . . . . . . . . . . . . . . . 87
Fuel Lines . . . . . . . . . . . . . . . . . . . . 87
Fuel Premix (Initial Fill) . . . . . . . . . 65
Fuel Pump . . . . . . . . . . . . . . . . . . . . 87
Fuel Recommendation. . . . . . . . . . . 69
Fuel System Deicers . . . . . . . . . . . . 70
Fuel Type Selection. . . . . . . . . . . . . 31
Fuel Warnings . . . . . . . . . . . . . . . . . 69
M
Maintenance Interval Table. . . . . 80-82
Maintenance Program . . . . . . . . . . . . 79
Maintenance Recommendations . . . . . 9
Maneuverability. . . . . . . . . . . . . . . . . 18
Metric/Standard Display . . . . . . . . . . 40
N
Noise . . . . . . . . . . . . . . . . . . . . . . . . . . 6
O
Odometer/Engine Hour Display Area 39
Oil Change, Chaincase . . . . . . . . . . . 85
Oil Filter . . . . . . . . . . . . . . . . . . . . . . 90
Oil Injection System . . . . . . . . . . . . . 66
Oil Level, Chaincase . . . . . . . . . . . . . 85
Oil Level, Injection . . . . . . . . . . . . . . 71
Oil Lines . . . . . . . . . . . . . . . . . . . . . . 90
Oil Recommendations . . . . . . . . . . . . 65
Operating in Deep Snow . . . . . . . . . . 16
Operation Warning . . . . . . . . . . . 24-25
Operator Safety . . . . . . . . . . . . . . . 8-20
Overheating, Engine . . . . . . . . . . . . . 92
H
Handlebar Adjustments . . . . . . . . . . 55
Handlebar Angle . . . . . . . . . . . . . . . 55
Handlebar Position. . . . . . . . . . . . . . 55
Headlight Adjustment . . . . . . . . . . . 28
Headlight Lamp Replacement . . . . . 99
Hood Fasteners . . . . . . . . . . . . . . . . 61
Hood/Side Panel Access . . . . . . . . . 83
Hot Surface Warning. . . . . . . . . . . . 23
I
Ice and Snow Build-up . . . . . . . . . . 16
Inadequate Snow Conditions. . . . . . 16
Indicator Lights . . . . . . . . . . . . . . . . 35
Information Display Area . . . . . . . . 38
Inspection, Pre-Ride . . . . . . . . . . . . 56
Instrument Cluster . . . . . . . . . . . . 34-49
Intake Filters . . . . . . . . . . . . . . . . . . 87
Intake Silencer . . . . . . . . . . . . . . . . . 18
P
Parking Brake Lever Lock. . . . . . . . . 60
Passenger Warning . . . . . . . . . . . . . . 22
Playback Function . . . . . . . . . . . . . . . 39
Polaris Products and Part Numbers . 122
Pre-Ride Checklist. . . . . . . . . . . . . . . 56
Pre-Ride Suspension Inspection . . . . 57
Pressure Cap Warning . . . . . . . . . . . . 21
138
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INDEX
Q
S
QUICKDRIVE Belt . . . . . . . . . . . . . 29
Survival Preparation . . . . . . . . . . . . . 12
Suspension Adjustments. . . . . . . 50-54
Suspension Inspection, Pre-Ride . . . 57
Suspension Lubrication, Rear. . . . . . 84
Suspension Set-Up, Fine Tuning . . . 52
Switches
R
Rail Slide Wear. . . . . . . . . . . . . . . . 112
Recoil Rope Inspection. . . . . . . . . . . 61
Registration, Warranty . . . . . . . . . . 128
Reverse Operation. . . . . . . . . . . . 74-75
Reverse Warning. . . . . . . . . . . . . . . . 22
Rider Capacity . . . . . . . . . . . . . . . . . 13
Rider Information Center . . . . . . 36-49
Riding Apparel . . . . . . . . . . . . . . . . . 11
Riding Position . . . . . . . . . . . . . . . . . 10
Engine Stop Switch . . . . . . . . . . . 72
Mode/Select Buttons . . . . . . . . . . 34
Mode/Set Switch . . . . . . . . . . . . . 34
Throttle Safety Switch . . . . . . . . . 72
T
Taillight/Brakelight Replacement. . . 99
Throttle Lever . . . . . . . . . . . . . . . . . . 73
Throttle Lever Inspection . . . . . . . . . 58
Throttle Safety Switch . . . . . . . . . . . 72
Throttle Safety Switch Inspection . . 58
Tool Kit. . . . . . . . . . . . . . . . . . . . . . . 28
Towing . . . . . . . . . . . . . . . . . . . . . . . 77
Track
Alignment . . . . . . . . . . . . . . . . . 108
Inspection. . . . . . . . . . . . . . . . . . 105
Lubrication. . . . . . . . . . . . . . . . . 105
Tension. . . . . . . . . . . . . . . . 106-107
Track Care for Storage . . . . . . . . . . 117
Track Inspection . . . . . . . . . . . . . . . . 61
Track Maintenance . . . . . . . . . 105-108
Track Safety . . . . . . . . . . . . . . . . . . . 10
Track Warm-Up . . . . . . . . . . . . . . . . 68
Track Warning . . . . . . . . . . . . . . . . . 23
Transporting the Snowmobile. . . . . 116
Troubleshooting, Drive Belt . . . . . . 125
Troubleshooting, Drive System . . . 124
Troubleshooting, Engine. . . . . . . . . 123
Troubleshooting, Suspension . . . . . 126
Tune-Up . . . . . . . . . . . . . . . . . . . . . 116
S
Safety Labels. . . . . . . . . . . . . . . . 21-24
Safety Symbols . . . . . . . . . . . . . . . . . . 8
Shock Compression Damping . . . . . 53
Side Panel Access . . . . . . . . . . . . . . . 83
Side Panel Fasteners . . . . . . . . . . . . . 61
Signal Words. . . . . . . . . . . . . . . . . . . . 8
Ski Alignment. . . . . . . . . . . . . . . . . 110
Ski Skags. . . . . . . . . . . . . . . . . . . . . 111
Slide Rail and Track Cooling . . . . . . 68
Snow Conditions. . . . . . . . . . . . . . . . 16
Spark Plug Condition . . . . . . . . . . . . 89
Spark Plug Inspection . . . . . . . . . . . . 89
Spark Plug Recommendations . . . . . 88
Spark Plugs . . . . . . . . . . . . . . . . . 88-89
Specifications
600 RMK . . . . . . . . . . . . . . 118-119
800 RMK . . . . . . . . . . . . . . 120-121
Speed. . . . . . . . . . . . . . . . . . . . . . . . . 13
Speed Display . . . . . . . . . . . . . . . . . . 38
Spring Preload. . . . . . . . . . . . . . . . . . 54
Standard/Metric Display. . . . . . . . . . 40
Starting the Engine . . . . . . . . . . . 63-64
Starting the Engine, Restarting . . . . . 64
Steering Inspection . . . . . . . . . . . . . 109
Steering System . . . . . . . . . . . 109-112
Steering System Inspection. . . . . . . . 61
Stopping, Emergency . . . . . . . . . . . . 76
Storage Procedures . . . . . . . . . 116-117
Storage, Cargo . . . . . . . . . . . . . . . . . 28
Storage, Daily . . . . . . . . . . . . . . . . . . 77
Storage, Tools . . . . . . . . . . . . . . . . . . 28
V
Vehicle Identification Numbers . . . . . 7
W
Windchill . . . . . . . . . . . . . . . . . . . . . 20
139
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