Polaris 800 PRO RMK manual

PMS 419 Modifications to this snowmobile are not recommended and may result in voided warranty coverage. Please read the warranty section of this manual carefully . IMPORT ANT NOTICE T O OWNER Snowmobile Owner's Manual for Maintenance and Safety 600 RMK 600 PRO RMK 800 RMK 800 PRO RMK 800 RMK ASSAUL T[...]

W ARNING Read, understand, and follow all of the in structions and safety precautions in this manual and on all produ ct labels. Failure to follow the safety precautions could result in serious injury or death . W ARNING The engine exhaust from this p roduct contains chemicals known to the S tate of California to cause cancer , birth defects or oth[...]

1 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. ?[...]

2 The following are registered trademarks of POLARIS Industries Inc.: 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 [...]

3 T ABLE 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 T[...]

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5 INTRODUCTION Import ant 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. Y our model may differ . Follow the maintenance program outline[...]

6 INTRODUCTION Preservation of the Environment POLARIS is committed to supporting an environmental education campaign. W e encourage state and provincial governments across the snowbelt to adopt rigorous safety training programs that encourage protection of our environment, inclu ding wildlife and vegetat ion. Snowmobile clubs and other or gan izat[...]

7 INTRODUCTION V ehicle 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. Y our 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. [...]

8 SAFETY Operator Safety The following signal words and symbol s appear througho ut this manual and on your vehicle. Y our safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symb ol ind icates a potential personal injury haza rd. DANGER A DANGER indicates a hazar[...]

9 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. Driving a snowmobile requires your full attention. DO NOT drink alcohol or use drugs or medications before or while dr[...]

10 SAFETY Operator Safety St ay Clear of T rack Y our snowmobile is propelled by a revolving track that must be partially exposed for proper operation. Do not stand on the plastic flap. W ARNING! Serious injuries may result if hands, feet, or clothing become entangled in the track. Be alert when riding, and remain properly seated to st ay clear of [...]

11 SAFETY Operator Safety Riding App arel Helmet W earing 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 T ransportation (DOT) label. Approved helmets in Europe, Asia and Oceania b[...]

12 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 Prep aration For your safety , always ride in a group of other sno[...]

13 SAFETY Operator Safety Rider Cap acity This snowmobile is designed for a single rider only . Never carry a passenger on this snowmobile. Excessive Speed W ARNING! 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[...]

14 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 di[...]

15 SAFETY Operator Safety A valanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain: • T ake an avalanch e cl ass • T ravel with experienced people • T ravel on designated trails • Make sure each person is equipped with a shovel, probe and avalanche beacon. Y ou don't have to be sno[...]

16 SAFETY Operator Safety Ice and Snow Build-up W ARNING! Ice and snow build-up may interf ere with the steering of your snowmobile, resulting in serious injury or death. Ke ep the und erhood 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 s[...]

17 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. W ARNING! When driving on lon g downh[...]

18 SAFETY Operator Safety Drive Belt Do not operate the engine with the drive belt r emoved. 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. Int ake Silencer Do not operate the engine with the intake silencer o[...]

19 SAFETY Operator Safety Driving Responsibly Every snowmobile handles differen tly , 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 [...]

20 SAFETY Operator Safety Windchill/T emperature Charts The following information is provided to help you determine when temperatures become dangerous for riding. WINDCHILL CHART (°F) WINDCHILL CHART (°C) Wind S peed in MPH Actual Thermometer Reading ( ° F) 40 35 30 25 20 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45 Equivalent T emperature ( ° [...]

21 SAFETY Safety Labels and Locations W arning 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[...]

22 SAFETY Safety Labels and Locations “No Passenger” W arning Snowmobiles designed for a single rider only have the NO P ASSENGER warning label on the lower left side of the console: W ARNING This vehicle is designed for operator only . NO P ASSENGER Reverse W arning The reverse warning label is located on the console, ei ther beside the steeri[...]

23 SAFETY Safety Labels and Locations T rack W arning The track warning label is on the rear tunnel: W ARNING St ay 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 W arning The hot surface warning is on the rear center of the tunnel. W ARNING Hot Surface[...]

24 SAFETY Safety Labels and Locations Operation W arning The operation warning label is also located on the console. W ARNING • T o avoi d serious in j ury or death, read and understand all warnin gs and the Owner's Manual before op eration. If manual is missing, contact a POLARIS deal er for a replacement. • This vehicle is cap able of hi[...]

25 SAFETY Safety Labels and Locations Operation W arning • When operating with a p assenge r (on approved models only) reduce speed and allow extra sp ace for steering and stopping. A p assenger reduce s your abilit y to control the vehicle. • When operatin g on hard-packed snow, ice, or when crossing road s, steering and braking ability are gr[...]

26 FEA T URES 8 13 5 6 7 12 11 2 1 3 4 10 9 1. Nosepan 2. Skis 3. Front Bumper 4. Hood 5. Headlight 6. W indshield (accessory) 7. Handlebar 8. Operator Seat 9. T a illight 10. Rear Bumper 11 . S n o w F l a p 12. Suspension 13. T rack 14. Side Panel 15. Side Panel Fasteners 15 14[...]

27 FEA TURES 1. Fuel Filler Cap 2. Instrument Cluster 3. Ignit ion Switch 4. Engine Stop Switch 5. Throttle Control 6. Recoil St arter Handle 7. Brake Lever 8. Parking Brake Lock 9. Handlebar Gr ip Warmer Switch 10. Thumbwarmer Switch 1 1. Electronic Reve rse Button 12. Mode Switch 13. Headlight Dimmer Switch 1 3 4 5 6 2 12 11 13 8 9 10 7 PRO-RMK/A[...]

28 FEA T URES S torage Bag/T ool Kit A storage bag and tool kit is located under the left side panel between the oil bottle and console. 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 cap[...]

29 FEA TURES 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 Pe[...]

30 FEA T URES 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 • V oiding of warranty • Injury to self[...]

31 FEA TURES Fuel T ype 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 reco mmended 91 non-ethanol gasoline, always select the “91-non” setting. Whenever in doubt of your fuel pur chase, use the “Eth” setting as a safe[...]

32 FEA T URES Detonation Elimination T echnology (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 ac[...]

33 FEA TURES Detonation Elimination T echnology (DET) The most likely causes of severe detonation are outlined in the troubleshooting table below . DET T roubleshooting Security System (Ignition Lock System) Y our snowmobile has an optional security function that can be activated by an authorized POLARIS dealer . If you have this feature activated,[...]

34 FEA T URES Instrument Cluster 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. NOTICE: Certain products will damage the lens and other plastic surf[...]

35 FEA TURES 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-T emperature Indicator This indicator illuminates to alert the operato[...]

36 FEA T URES 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 engin[...]

37 FEA TURES 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. T o change the display , see page 38. 2. Speed Display - The speed display area displays either vehicle speed [...]

38 FEA T URES Instrument Cluster Rider Information Center Spe ed Display Area The speed display area displays either vehicle speed or engine speed. V ehicle 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. T o change which item displays, first make sure th[...]

39 FEA TURES Instrument Cluster Rider Information Center Odometer/Engine Hour Display Area This area displays the odometer , T rip A meter , T rip 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[...]

40 FEA T URES Instrument Cluster Rider Information Center St andard/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. Pr ess and r elease the MODE button or MO[...]

41 FEA TURES Instrument Cluster Rider Information Center Security System (Ignition Lock Syste m) 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 [...]

42 FEA T URES Instrument Cluster Rider Information Center Security System (Ignition Lock Syste m) First T ime Use of Y our Security System Perform all tasks in the or der shown if you wish to activate and use the optional security system. T ASK 1: Activate the security system See your authorized POLARIS dealer to have the optional security system f[...]

43 FEA TURES Instrument Cluster Rider Information Center Security System (Ignition Lock Syste m) First T ime Use of Y our Security System T ASK 3: Unlock the System 1. When the engine is runn ing, the display w ill alternate between SECURE ON and ENTER CODE. Wait until ENTER CODE displays, then press and release SEL to advance the digit. When “0?[...]

44 FEA T URES Instrument Cluster Rider Information Center Security System (Ignition Lock Syste m) Locking the System Wit h Y our Personal Security Code 1. S tart 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 no t, repeat this step. 3. W ait until ENT[...]

45 FEA TURES Instrument Cluster Rider Information Center Security System (Ignition Lock Syste m) Unlocking the System With Y our Personal Security Code 1. When the engine is running, the display will alternate between SECURE ON and ENTER CODE. W ait until ENTER CODE displays, then press and release SEL to advance the di git. When the fi rst digit o[...]

46 FEA T URES Instrument Cluster Rider Information Center Security System (Ignition Lock Syste m) Changing to a New Security Code Any time you wish to change your curre nt security code to a new code, perform T ASK 2 through T ASK 4 of the First Time Use of Y our Security System procedure beginning on page 42. Instead of using the factory default c[...]

47 FEA TURES Instrument Cluster Rider Information Center Diagnostic Display Mode The diagnostic display mode is for informational pu rposes 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 diagnosti c code is active. Do not stop the engin[...]

48 FEA T URES 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-Gr ound: The wire is shorted to ground between the electronic control unit and the item listed in the chart. S[...]

49 FEA TURES Instrument Cluster Rider Information Center Diagnostic Display Code Definitions Diagnostic Codes Component Condition SPN FMI ECU Memory Checksum/CRC Error 628 13 Injector 1 (MAG) (Port Injector) Driver Circuit Open/Grounded 651 5 Driver Circuit Short to B+ 3 Injector 2 (PTO) (Port Injector) Driver Circuit Open/Grounded 652 5 Driver Cir[...]

50 THE PERFECT FIT Suspension Adjustment s Factory settings, combined with user adjustments to the rear track shock spring (R TSS), should be all that’ s necessary to provide the best riding experience for most riders. The primary adjustment for overall vehicle balance is R TSS preload. Perform this adjustment first. Always perform shock spring p[...]

51 THE PERFECT FIT Suspension Adjustment s 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. (7 3-100 kg) weight range, adjust the factory-set preload to the following installed lengths as a starting point, then test ride before making fi[...]

52 THE PERFECT FIT Suspension Adjustment s Fine-T uning Y our Suspension Set-Up The primary adjustment for overall vehicle balance is R TSS 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 n[...]

53 THE PERFECT FIT Suspension Adjustment s Shock Compression Da mping (RMK/ASSAUL T RMK) The primary adjustment for overall vehicle balance is R TSS preload. Perform this adjustment first. See page 50. After adjusting R TSS preload to your satisfaction, compression damping adjustments can be made to control ride quality and bottoming resistance. 80[...]

54 THE PERFECT FIT Suspension Adjustment s Independent Front Suspension and Front T rack 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 R [...]

55 THE PERFECT FIT Handlebar Adjustment s 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. T ighten the bolts. Handlebar Angle 1. Loosen the four bolts on the top of the adjus[...]

56 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 101 S teering System 61 Recoil Rope 61 Coolant Leve l 91 Chaincase Oil Level 85 Injection Oil Level 71 Parking[...]

57 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 suspen[...]

58 PRE-RIDE INSPECTIONS Before St arting 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. W ARNING! Operating the vehicle with worn, damaged, or malfunctioning components could result in seriou[...]

59 PRE-RIDE INSPECTIONS Before St arting the Engine Brakes Always check the following items for proper operation before starting the engine. Brake Lever T ravel Squeeze the brake lever . It should move no closer to the handgrip than 1/2 inch (1.3 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system. Refer to the br[...]

60 PRE-RIDE INSPECTIONS Before St arting the Engine Parking Brake Lever Lock Use the parking brake lever lock only when you want the snowmobile to remain stationary; for example, when parked on an incline for a period of five minutes or less. 1. Brake Lever 2. Parking Brake Lever Lock 3. Master Cylinder Reservoir/ Cover 4. Fluid Level Indicator Loc[...]

61 PRE-RIDE INSPECTIONS Before St arting the Engine Steering System W ARNING! Ice and snow build-up may interf ere with the steering of your snowmobile, resulting in serious injury or death. Keep the und erhood 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 fu[...]

62 PRE-RIDE INSPECTIONS S t art 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 Be fore Starting the Engine beginning on page[...]

63 OPERA TION S t arting the Engine NOTICE: Engaging the starter when the engine is run ning WILL result in serious engine damage, especially if the transmission is in reverse. Never engage the starter when the engine is runni ng. 1. T u rn the key to the ON position. 2. Pull the engine stop switc h up to the RUN position. 3. If equipped with elect[...]

64 OPERA T ION S t arting the Engine Rest arting an En gine 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. T u rn the key to the OFF position. 3. W ith bo[...]

65 OPERA TION 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[...]

66 OPERA T ION 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 fi rst three hours of use. V ary the throttle openings and vehicle speeds to reduce friction on all close- fitting mach[...]

67 OPERA TION Break-In Period Drive Belt/QUICKDRIVE Belt Break-In The length of the break-in period var ies 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). • V ary the throttle position and limit full throttle use. • Always [...]

68 OPERA T ION T rack W arm-Up W ARNING! A loose track or flying debris could cause serious injury or death. S tand clear of the front of the sno wmobile and the moving tra ck. Never hold the snowmobile up or stand be hind it while warming up the track. Do not use excessive throttle during warm-up or when the track is free-hanging. Use a stable rea[...]

69 OPERA TION Fuel Gasoline is highl y flammable and explosive under certain conditions. • Always exercise extreme caution w henever handling g asoline. • 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 f[...]

70 OPERA T ION 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 mor e than 10% ethanol. Never use E85 fuel in your[...]

71 OPERA TION 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. 1. Immediately stop the engine if the low oil indicator light comes on. 2. Open the left side panel. 3. V iew the oil level in the oil bottle. 4. Add oil as needed before ope[...]

72 OPERA T ION Engine St op 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. 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[...]

73 OPERA TION Throttle Lever W ARNING! An improperly functioning thro ttle lever may cause erratic snowmobile behavior a nd loss of control, wh ich could resu lt in serious injury o r 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. T u rn the ignitio[...]

74 OPERA T ION Electronic Reverse (PERC) 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[...]

75 OPERA TION Electronic Reverse (PERC) Engaging Reverse 1. S top 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 releas e. The engine will automatical ly reduce RPM and start a reverse rotation. A flashing reverse light [...]

76 OPERA T ION Emergency S topping 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 WHA T IT DOES Ignition Switch Interrupts ignition circuit Brake Slows jackshaft Engine S top Switch Interrupts ignition circu[...]

77 OPERA TION Daily St orage 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 inch es (10 cm) of f the ground. Remove the key and cover the snowmobile. To w i n g For your safety , do not attempt to use a tow hitch until you&apos[...]

78 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 Y our snowmobile is equipped at the time of sale with an emission control information (ECI) label and a factory-installed emissions information [...]

79 MAINTENANCE POLARIS Recommended Maintenance Program T o 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 sche dule on your snowmobile calls[...]

80 MAINTENANCE Periodic Maintenance Interval T able The following chart is a guide based on average riding conditions. Y ou may need to increase frequency based on riding conditions. When inspection reveals the need for rep lacement parts, always use genuine POLARIS parts, available from your POLARIS dealer . I - Inspect (clean, adjust, tighten, lu[...]

81 MAINTENANCE Periodic Maintenance Interval T able Item See Page Frequency 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi. (3200 km) Pre- Season BRAKES Hose Routing -- II II Hose Condition -- II II Fluid Leaks -- II II Brake Pads 96 II II Brake Disc -- II II Parking Brakes 60 II II Brake System 59, 96 I Brake Fluid 97 I FUEL MANAGEME[...]

82 MAINTENANCE Periodic Maintenance Interval T able I - Inspect (clean, adjust, tighten, lubricate, replace if necessar y) C - Clean R - Replace L - Lubricate Bolt T orque Inspection T o maintain proper chassis performance, see your POLARIS dealer for a bolt torque inspection every 1000 miles (1600 km). Item See Page Frequency 150 mi. (240 km) 500 [...]

83 MAINTENANCE Hood/Side Panel The hood and side pa nels 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. T o open a side panel, rotate the two 1/4-turn fasteners at the uppe[...]

84 MAINTENANCE Lubrication Rear Suspension Lubricate the suspension pivot shafts with POLARIS All Season Grease at the intervals outlined in the Periodic Maintenance T able 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 af fect y[...]

85 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 1. Position th[...]

86 MAINTENANCE Lubrication Driveshaf t Bearing (RMK/ASSAUL T RMK) Inject grease into the fitting on the 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. Fitting[...]

87 MAINTENANCE Int ake 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 . Fuel Pump All fuel pump service must be performed by an authorized POLARIS dealer . Do not attempt to service the fuel pump. Fuel Filter/Fu[...]

88 MAINTENANCE Spar k P l u g s Sp ark Plug Recommendations A new engine can cause temporary sp ark plug fouling due to the preservative added during the assembly process. A void 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 th[...]

89 MAINTENANCE Spar k P l u g s Sp ark Plug Insp ection 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 cau[...]

90 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.[...]

91 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 [...]

92 MAINTENANCE Cooling System Engine Overheating The over-temper ature indicator on the instrument cluster will illuminate when the engine is overheating. The indicator will flash when engine temperature reaches critical levels. Illuminated Indicator T ake action to cool the engine: • Drive in loose snow . • V iew the coolant level. Do not open[...]

93 MAINTENANCE Cooling System Bleeding the Cooling System CAUTION! S team and hot liquids will cause burn s 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, contac[...]

94 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 part s can cause burns. Allow adequate time for the exhaust system to cool. Never perform this procedure with the engine running[...]

95 MAINTENANCE Drive Chain T ension (RMK/ASSAUL T RMK) Check drive chain tension weekly and before each long t rip. 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[...]

96 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 . W ARNING! Brake failure du[...]

97 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 pag[...]

98 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. W ARNING! Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an accident and lead to serious in jury or death. Never operate [...]

99 MAINTENANCE Light s When servicing a halogen lamp, avoi d 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. Re[...]

100 MAINTENANCE Clutch System Periodically inspect clutch sheaves for damage, wear or belt residue. T o maintain optimum performance, clean with non-oil based cleaners such as isopropyl alcohol. W ARNING! If you become aware of higher than normal clutch engagement or an unusual vibration or shift pattern, see your dealer immediatel y . Do not opera[...]

101 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 locate[...]

102 MAINTENANCE Clutch System Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge (1) on the belt and apply downward pressure while measuring at point 2. This measurement should be 1 1/4 inches (3.2 cm). Drive Belt Adjustment 1. Loosen the 7/16-inch jam nu t on the belt [...]

103 MAINTENANCE Clutch System Drive Belt Removal NOTICE: Do not attempt to remove the dri ve belt after opera ting in reverse. The snowmobile must be stop ped after forward moti on to prevent damage to components during belt removal. Rotate the driven clutch counte r- clockwise 1/4 turn by hand to ensure forward engagemen t be fore attempti ng to r[...]

104 MAINTENANCE Clutch System Drive Belt Inst allation 1. W ith 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 th e direction in which the belt was ori ginally installed. 2. W iggle the b[...]

105 MAINTENANCE T rack Maintenance T rack Inspection W ARNING! Broken track rods can cause a rotating track to come off the snowmobile, which could cause seri ous 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. Rot[...]

106 MAINTENANCE T rack Maintenance W ARNING! Moving part s can cut and crush body parts. When performing the checks and adjustments recommended on the following pages, stay clear of all moving part s. Never perform track measur ement or adjustme nts with the engine running. T rack T ension T rack adjustment is critical for proper handling. Always m[...]

107 MAINTENANCE T rack Maintenance T rack T ension 5. Check for specified slack between the wear surface of the track clip and the plastic slider . Refer to the Track T ension Data Chart on page 106. If the track needs adjustment: 6. Loosen the rear idler shaft bolt. 7. Loosen the locknuts. 8. T ighten or loosen the track ad justing screws to provi[...]

108 MAINTENANCE T rack Maintenance T rack 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 t he rear of the snowmobile with the track off the ground. 2. S tart the engine and apply a small amount of throttle until the [...]

109 MAINTENANCE S teering System Steering Inspection Each week, or before a long ride, check all steering system fasteners and tighten if necessary .[...]

110 MAINTENANCE S teering System Ski Alignment W ARNING! Improper ski alignment or adjust ment may cause loss of steering control, resulting in se rious injury or d eath. 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. W ith only vehicle weight compr[...]

111 MAINTENANCE S teering System Ski Skags W ARNING! Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causing seri ous injury or death. See your dealer's studding chart fo r recommended skags. If you install longer or more aggressi ve carbide skags than the original equipment, it may also be ne cessary[...]

112 MAINTENANCE S teering System Rail Slide Wear For ease of inspection, all POLARIS rail slides have a wear limit indicator groove to indicate the 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 ra[...]

113 MAINTENANCE Battery (if equipped) W ARNING! Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death . Wh en removin g the battery , always disconnect the negative (black) ca ble first. When reinstalling the battery , always connect the negative (black) cable last. Battery Removal 1. Rem[...]

114 MAINTENANCE Battery Battery S torage 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 char ged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and rechar ge as needed to maintain a full charge. Tip : Battery [...]

115 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 . T[...]

116 MAINTENANCE Fall T une-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. T ransporting the Snowmobile Whenever the snowmobile is transported: 1. Be sure the fuel cap and oil cap are installed correctly . [...]

117 MAINTENANCE Extended Storage Controls and Linkage Lubricate all bushings and cables as outlined in the Periodic Maintenance T able 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 Manua[...]

118 SPECIFICA T IONS 600 RMK / 600 PRO RMK Cap acities and Dimensions Body Style PRO-RIDE Rider Capacity 1 Coolant Capacity 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 9 oz. (266.2 ml) (600 RMK) N/A (600 PRO RMK) Fuel T ank Capacity 1 1.5 gal. (43.5 l) Gearcase Oil Ca pacity (oz./ml) N/A[...]

119 SPECIFICA T IONS 600 RMK 144 / 600 RMK 155 600 PRO RMK 155 Clutching Chart AL TI TUDE Meters (Feet) Drive Clutch Shif t Weight Drive Clutch Spri ng Driven Clu tch Spr i ng Driven Helix Chaincase Gearing/ Pitch *Shaded cells indicate factory settings. 0-450 (0-1500) 10-64 (1321585) Black/Green (7042083) LH BLK PUR TEAM L W (7043363) (56/42/.36) [...]

120 SPECIFICA T IONS 800 RMK / 800 PRO RMK / 800 RMK ASSAUL T Cap acities and Dimensions Body Style PRO-RIDE Rider Capacity 1 Coolant Capacity 6.3 qts. (6.0 l) (RMK 155) 5.3 qts. (5.0 l) (PRO RMK 155) 5.3 qts. (5.0 l) (RMK ASSAUL T 155) 5.5 qts. (5.2 l) (PRO RMK 163) Chaincase Oil Capacity 9 oz. (266.2 ml) (RMK/RMK ASSAUL T) N/A (PRO RMK) Fuel T an[...]

121 SPECIFICA T IONS 800 RMK 155 / 800 RMK ASSAUL T 155 800 PRO RMK Clutching Chart AL TI TUDE Meters (Feet) Drive Cl utch Shift W eight Drive Clutch Spri ng Driven Clutch Spri ng Driven Helix Chaincase Gearing/ Pitch *Shaded cells indicate factory settings. 0-600 (0-2000) 10-68 (1322427) 140/330 (7043829) LH BLACK T eam (7043063) (56/42/ .36) LW E[...]

122 POLARIS PRODUCTS Part No. Description Engine L ubricant s 2870791 Fogging Oil (12 oz. Aerosol) 2875035 Premium Blue 2-Cycle O il (qt./.95 l) (break-in only) 2875036 Premium Blue 2-Cycle Oil (gal./3.8 l) (break-in only) 2877882 VES 2-Cycle Oil (qt./.95 l) 2877953 VES 2-Cycle Engine Oil (2 qt./1.9 l) 2877883 VES 2-Cycle Engine Oil (gal./3.8 l) 28[...]

123 TROUBLESHOOTING Engine T roubleshooting Problem Probable Ca use Solution Erratic engine RPM during acceleration or load variations Drive clutch binding • SEE YOUR DEALER. 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 , [...]

124 TROUBLESHOOTING Drive System T roubleshooting Problem Probable Ca use Solution Machine fails to move Clutch jammed • Check for twisted belt or broken spring. SEE YOUR DEALER. T rack jammed • Foreign ob ject may be caught or the rail slide melted to the track cli ps due to lack of lubrication. • T r ack may be iced up or frozen to the grou[...]

125 TROUBLESHOOTING Drive Belt T roubleshooting Belt W ear/Burn Diagnosis Causes Solutions Driving at low RPM • Drive at higher RPMs. Gear the machine down. Check belt deflection. Insufficient warm-up • W arm the engine at least five minutes. T ake the drive belt off the snowmobile in extremely cold weather and warm it up. Break snowmobile loos[...]

126 TROUBLESHOOTING Suspension T roubleshooting 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 [...]

127 W ARRANTY Service and W arranty Information Obt aining Service and W arranty 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 . Y our dealer receives frequent updates on changes, modifications and tips on snowmobi[...]

128 W ARRANTY Limited W arranty POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIMITED W ARRANTY on all components of the POLARIS snowmobile against defects in material or workmanship. W arranty period will vary regionally . This warranty covers the parts and labor char ges for repair or replacement of defective parts th[...]

129 W ARRANTY Limit ations of warranties and re medies ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W ARRANTIES O F MERCHANT ABILITY AND FITNESS FOR A P AR TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE ONE YEAR W ARRANTY PERIOD. POLARIS FUR THER DISCLAIMS ALL EXPRESS W ARRANTIES NOT ST A TED IN THIS W A RRANTY . Some s[...]

130 W ARRANTY Conditions and Exclusions In order to qualify for warranty , the product must have been properly set up and tested by a POLARIS Dealer (if app licable). 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 v[...]

131 W ARRANTY Exported V ehicles EXCEPT WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W ARRANTY OR SER VICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER'S AUTHORIZED LOCA TION. This policy does not apply to vehicles that have received authorization for export from POLARIS Industries. Dealers m[...]

132 W ARRANTY 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 c overage will be denied. Y ou must nonetheless warranty register your vehicle under your name and address with a local POLARIS dealer in your[...]

133 W ARRANTY U.S.A. EP A Emissions Limited Warranty This emissions limi ted warranty is in additi on to the POLARIS standard limited warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehi cle is designed, built and equipped so it conforms with applicable U.S. Environmental [...]

134 W ARRANTY U.S.A. EP A Emissions Limited Warranty The exclusive remedy for breach of this limited warrant y shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE REMEDIES SET FOR TH IN THIS LIMITED W ARRANTY ARE THE ONL Y REMED IES A V AILABLE TO ANY PERSON FOR BREACH OF THIS [...]

135 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. DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi. (32[...]

136 MAINTENANCE LOG DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

137 INDEX A Accessori es . . . . . . . . . . . . . . . . . . . . 30 Air Pollutio n . . . . . . . . . . . . . . . . . . . . 6 Avalanches . . . . . . . . . . . . . . . . . . . . 15 B Battery . . . . . . . . . . . . . . . . . . 113-115 Charging . . . . . . . . . . . . . . . 114-115 Installation . . . . . . . . . . . . . . . . . 113 Removal . . . . . .[...]

138 INDEX F Fasteners, Hood and Side Panel. . . . 61 Fluid Change Chaincase . . . . . . . . . . . . . . . . . . 85 Coolant . . . . . . . . . . . . . . . . . . . . 92 Fluid Level Brake Fluid . . . . . . . . . . . . . . . . . 97 Chaincase . . . . . . . . . . . . . . . . . . 85 Coolant . . . . . . . . . . . . . . . . . . . . 91 Fuel . . . . . . . . . [...]

139 INDEX Q QUICKDRIVE Belt . . . . . . . . . . . . . 29 R Rail Slide We ar . . . . . . . . . . . . . . . . 112 Recoil Rope Inspection . . . . . . . . . . . 61 Registration, Warranty . . . . . . . . . . 128 Reverse Operation. . . . . . . . . . . . 74-75 Reverse Warning. . . . . . . . . . . . . . . . 22 Rider Capacity . . . . . . . . . . . . . . . .[...]

For your nearest Polaris dealer , call 1-800-POLARIS or visit www .polaris.com Polaris Sales Inc., 2100 Hwy . 55, Medina, MN 55340 Phone 1-888-704-5290 Part No. 9924268 Rev 01 Printed in USA PMS 419 *9924268 *[...]