Polaris 600 RMK Shift Owner's Manual
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Polaris 600 RMK Shift Owner's Manual

Polaris 2009 snowmobile owner's manual
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  • Page 3 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. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
  • Page 4 • RANGER utility vehicles • Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre- ational vehicles manufactured in the world today. Many years of experi- ence have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever produced.
  • Page 5 POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus- tries Inc. Copyright 2008 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant...

  • Page 6: Table Of Contents

    Polaris Products..... . . 110 Troubleshooting ..... . . 111 Warranty .

  • Page 8: Introduction

    INTRODUCTION Important Notes for Owners and Drivers After reading this manual, store it in the snowmobile for convenient ref- erence. It should remain with the snowmobile when the snowmobile is sold. Some of the illustrations and photos used in this manual are general rep- resentations.

  • Page 9: Preservation Of The Environment

    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.
  • Page 10 Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using your key num- ber) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.

  • Page 11: Safety

    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 sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, indicates the potential for serious injury.

  • Page 12: Operator Safety

    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.
  • Page 13 Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. Serious injuries may result if hands, feet, or clothing become entangled in the track. Be alert when riding, and remain properly seated to stay clear of the track.

  • Page 14: Survival Preparation

    Operator Safety Riding Position Operating a snowmobile requires skill and balance for proper control. Rider positions may vary with experience; 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.

  • Page 15: Eye Protection

    Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever 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.

  • Page 16: Disabled Operators

    Do not allow disabled persons to operate this vehicle. Rider Capacity Your Polaris snowmobile is designed for a single rider only. Do not carry a passenger. Excessive Speed High speed driving, especially at night, could result in serious injury or death.

  • Page 17: Driver Awareness

    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.
  • Page 18 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.

  • Page 19: Driving Downhill

    SAFETY Operator Safety Ice and Snow Build-up 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.

  • Page 20: Driving On Slippery Surfaces

    Operator Safety Driving on Slippery Surfaces Never attempt an abrupt change of direction when operating on slippery sur- faces. 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.

  • Page 21: Drive Belt

    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. 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.

  • Page 22: Operating In Deep Snow

    Operator Safety 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.

  • Page 23: Driving Responsibly

    Operator Safety Driving Responsibly Every snowmobile handles differently, and even the most docile condi- tions may become dangerous if operators drive improperly. If you’re new to snowmobiling, acquaint yourself with the machine and with what it will and won’t do under various conditions. Even seasoned driv- ers should spend some time getting the feel for a machine before attempting ambitious maneuvers.
  • Page 24 Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when tem- peratures become dangerous for riding. WIND CHILL CHART (°F) Wind Speed Calm Frostbite in >> 30 min. WIND CHILL CHART (°C) Wind Speed Calm -10 -13 -17 -21 -24 -28 -32 -36 -39 -43 -47 -50 -54 -58 -62 -11 -15 -19 -22 -26 -30 -34 -38 -42 -45 -49 -53 -57 -61 -65 -12 -16 -20 -24 -28 -32 -36 -39 -43 -47 -51 -55 -59 -63 -67 -13 -17 -21 -25 -29 -33 -37 -41 -45 -49 -53 -57 -61 -65 -69...

  • Page 25: Clutch Cover Warning

    If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.

  • Page 26: Track Warning

    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. SAFETY “No Passenger”...

  • Page 27: Reverse Warning

    Flashing light on dash indicates reverse operation. • Push button again to return to forward. Operation Warning The operation warning decal is located on the console of all Polaris snowmobiles. WARNING • To avoid serious injury or death, read and understand all warnings and the Owner’s Manual before operation.

  • Page 28: Safety Decals And Locations

    Safety Decals and Locations Operation Warning (continued from previous page) • 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. •...

  • Page 29: Features

    FEATURES 1. Front Bumper (do not use for pulling or dragging the snow- mobile) 2. Hood 3. Headlight 4. Windshield 5. Mountain Bar (if equipped) 6. Handlebar 7. Seat 8. Taillights 9. Rear Bumper 10. Snow Flap 11. Track 12. Suspension 13.
  • Page 30 1. Fuel Filler Cap 2. Ignition Switch 3. MFD (Multi-Function Display) 4. Engine Stop Switch 5. Throttle Control 6. Recoil Starter Handle 7. Hood Hold-Down Straps 8. Brake Lever 9. Parking Brake 10. Handlebar Grip Warmer Switch 11. Thumbwarmer Switch 12.
  • Page 31 FEATURES Headlight Dimmer Switch Use the headlight dimmer switch to adjust the headlights between high beam and low beam. Switch headlights to low beam when meeting oncoming traffic. Dimmer Switch Dimmer Switch (Dragon) Adjustable Headlights Move the adjuster to the left to lower the headlight beam.

  • Page 32: Features

    FEATURES Detonation Elimination Technology (DET) A detonation sensor monitors the engine and responds to detonation by automatically reducing the engine timing and adding fuel. This results in decreased engine RPM and performance. Effect of DET The DET system prevents damage to the engine from detonation while developing the maximum power of the engine safely.

  • Page 33: Features

    FEATURES Instrumentation MFD Component Identification Item 1 Analog Gauge (if equipped) 2 Digital Gauge 3 Check Engine Indicator 4 Low Oil Indicator 5 High Temp Indicator 6 Brake Indicator 7 Reverse Indicator 8 High Beam Indicator...

  • Page 34: Features

    Instrumentation Digital Display Identification Item 1 RPM or Speed Altitude (if equipped) Service Interval 2 Electrical System Voltage Level 3 MAX - Maximum MPH/ KPH or RPM MPH -Miles per hour KPH - Kilometers per hour RPM -Engine crankshaft revolutions per minute 4 Air Temp (if equipped) Engine Temp...

  • Page 35: Features

    FEATURES Instrumentation MFD Settings The MFD Control Switch allows you to set the MFD display to your preferences. The rocker switch has a MODE button (top) and a SET but- ton (bottom). Specific instructions are outlined on the following pages. MFD Control Switch Standard vs.

  • Page 36: Features

    Instrumentation MFD Digital Display Programs Press and release the MODE button to cycle through the three MFD pro- grams: Performance, Engine and History. Each program remains active until you cycle to the next program. While any program is active, press and release the SET button to cycle through the program’s screens.

  • Page 37: Features

    FEATURES Instrumentation MFD Digital Display Programs Performance Program Trip Settings Trip F automatically displays when the fuel level is low if the snowmobile is equipped with an electronic fuel gauge. The fuel symbol and the last fuel bar on the MFD gauge (if equipped) will blink when the fuel level reaches 1/8 of a tank.

  • Page 38: Features

    Instrumentation MFD Digital Display Programs Engine Program Air Temperature (accessory) The MFD displays actual air temperature. Press and hold the MODE switch for ten sec- onds to switch between standard and metric units of measurement. Altimeter (accessory) The rider can calibrate the altimeter for cur- rent atmospheric conditions.

  • Page 39: Features

    FEATURES Instrumentation MFD Digital Display Programs History Program Press and release the MODE button until the history program screen is active. This screen will always display electrical system voltage level and fuel level (if equipped). Press and release the SET button to cycle through the following screens: maximum vehicle speed, maximum engine RPM and service interval reminder.

  • Page 40: Features

    Instrumentation MFD Digital Display Programs History Program Service Interval Reminder The gauge logs the number of engine hours accumulated between service reminders. When the logged hours reaches the desig- nated service interval (set by the user), the gauge provides a reminder that service is due.

  • Page 41: Features

    FEATURES Instrumentation Gauge Cleaning 1. Wipe the gauge face as needed using a clean cloth and a mild soap and water solution. Wipe dry with clean, soft cloth. 2. Clean the back side of the gauge using a clean cloth and a mild soap and water solution.

  • Page 42: The Perfect Fit

    THE PERFECT FIT IQ Front Suspension Adjustments Independent Front Suspension (IFS) Break in the suspension for approximately 150 miles (240 km) before making any fine-tuning adjustments. Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions. We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference.
  • Page 43 Air Shocks Walker Evans air shocks can be adjusted for preload and valving. Please see your Polaris dealer for these adjustments. Standard Shocks The tension at which the shock coil spring is set is called spring preload.
  • Page 44 (Standard Only) The front springs can be changed if spring preload alone isn't sufficient and further adjustment is desired to control suspension stiffness. See your Polaris dealer for more information. Front Shock Spring Rate (Assault Model) The Assault IFS shocks are equipped with an adjustable spring rate feature.

  • Page 45: Suspension Performance Tips

    Rear Suspension Adjustments Rider weight, riding style, trail conditions, and vehicle speed all affect suspension action. Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. However, all sus- pension designs and adjustments involve a compromise, or trade-off. For example, a suspension set up for snow-cross racing would provide a very stiff ride on the trail.

  • Page 46: Rear Suspension Adjustments

    Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) To set up the rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement X. Take this measurement with no rider and with the rear suspension at full extension.

  • Page 47: Torsion Spring Preload

    THE PERFECT FIT Rear Suspension Adjustments Torsion Spring Preload To adjust rear torsion spring preload, rotate the three-position cam using the engine spark plug tool. Different rate torsion springs are available if a firmer ride is desired. Contact your dealer for more information. The following information is provided only as a guideline to be used for initial suspension set-up.

  • Page 48: Shock Compression Valving

    Rear Suspension Adjustments Shock Compression Valving Standard Rear Track Shock The standard RMK rear track shock is an Arvin MPV Select shock that allows for adjustments to the compression valving. Adjustments are made by turning the adjustment screw located near the base of the shock.
  • Page 49 THE PERFECT FIT Handlebar Adjustments Some aftermarket accessories (including windshields and cargo bags) may interfere with the handlebar. Such accessories could limit your ability to steer the vehicle and/or may contact the brake lever. This could lead to loss of con- trol resulting in serious injury or death.

  • Page 50: Handlebar Position

    Handlebar Adjustments Handlebar Position 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.

  • Page 51: Tether Switch

    THE PERFECT FIT 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: •...

  • Page 52: 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 refer- enced pages. Look for a checkmark (n) on the referenced pages to locate the pre-ride inspection items. Drive Belt Condition Steering System Recoil Rope...

  • Page 53: Before Starting The Engine

    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. Operating the vehicle with worn, damaged, or malfunctioning components could result in serious injury or death.

  • Page 54: 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. n Brakes Always check the following items for proper operation before starting the engine.

  • Page 55: Parking Brake Lever Lock

    PRE-RIDE INSPECTIONS Before Starting the Engine n Parking Brake Lever Lock Use the parking brake lever lock only when you want the snow- mobile to remain stationary; for example, when parked on an incline for a period of five min- utes or less.

  • Page 56: Steering System

    The 2.4" powder track is designed specifically for deep snow applica- tions. Operation in low snow conditions at high speeds may cause track lug separation. Track lug separation is not covered under the Polaris limited warranty policy. Polaris does not recommend operation above 70 mph with this track.
  • Page 57 PRE-RIDE INSPECTIONS Before Starting the Engine n 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 follow- ing items on a weekly basis or before any long trip.

  • Page 58: Start The Engine And Check

    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 50.

  • Page 59: Operation

    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. Pull the engine stop switch up to the RUN position.
  • Page 60 Premix the first tank of gasoline with one pint of Polaris injection oil for each five gallons of fuel. This, in addition to the lubrication supplied by the injec- tion system, will assure proper engine break-in.

  • Page 61: Oil Injection System

    This snowmobile is equipped with a variable exhaust system (VES). Engine lubrication comes from oil added to the fuel and oil injection systems. Polaris recommends the use of VES II 2 Cycle Oil for this engine. See page 110 for the part numbers of Polaris products.

  • Page 62: Track Warm-Up

    Track Warm-Up A loose track or flying debris could cause serious injury or death. Stand clear of the front of the machine and the moving track. Never hold the snowmobile up or stand behind it while warming up the track. Do not use excessive throt- tle during warm-up or when the track is free-hanging.

  • Page 63: Fuel Safety

    Fuel Safety 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. •...

  • Page 64: Fuel System Deicers

    Fuel For peak performance, Polaris recommends the use of 91 octane or higher fuel. Although 87 octane fuel is usable, some engine perfor- mance 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 (including E85).

  • Page 65: Low Oil Indicator Light

    Never operate the engine if oil is not vis- ible in the tank. TIP: The Polaris oil cap on the oil bottle is vented to allow proper oil flow. See your Polaris dealer for recommended replacement parts.

  • Page 66: Engine Stop Switch

    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 RUN 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 valves do not return to the normal closed position.
  • Page 67 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 possi- ble. WARNING...

  • Page 68: Emergency Stopping

    Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 63 for more information about the engine stop switch. SYSTEM Ignition Switch Brake Engine Stop Switch Choke (if equipped) Throttle Safety Switch Tether Switch (if equipped) WHAT IT DOES Interrupts ignition circuit...
  • Page 69 OPERATION Electronic Reverse (PERCt) Electronic reverse will activate only if the engine RPM is below 4000. The maximum engine RPM will be 6000 when in reverse. 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.
  • Page 70 Electronic Reverse (PERCt) Engaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Make sure the area behind your snowmobile is clear. 3. Push the reverse button on the left- hand control for one second, then release. The engine will automatically reduce RPM and start a reverse rotation.

  • Page 71: Daily Storage

    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" (10 cm) off the ground. Remove the key and cover the snowmobile. Towing Do not use the front bumper to pull or drag the snowmobile.

  • Page 72: Maintenance

    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 con- trol information (ECI) label and a factory-installed emissions informa- tion hangtag.

  • Page 73: Emission Control Information

    Please read the Snowmobile Engine Emissions Limited Warranty, and read the maintenance section of your owner's manual. You are responsi- ble for ensuring that the specified maintenance is performed. Polaris recommends that you contact an authorized Polaris dealer to perform...
  • Page 74 If you're not familiar with safe service or adjustment procedures and the use of tools, or if you don't feel comfort- able 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 snowmo- bile on its side for service or inspection.

  • Page 75: Item See Page

    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 Clutch Alignment Offset...

  • Page 76: Throttle Lever

    Periodic Maintenance Interval Table Item Hose Routing Hose Condition Fluid Leaks Brake Pads Brake Disc Parking Brake Brake System Brake Fluid Idle RPM Throttle Lever Oil Pump Lever (synchronize) Throttle Cable Vent Lines Throttle Position Sensor Fuel Lines Fuel Filter Oil Filter Oil Lines Air Box/Plenum...

  • Page 77: Suspension Mounting Bolts

    Periodic Maintenance Interval Table Item Ski Toe Alignment Suspension Mounting Bolts Steering Fasteners Rear Suspension Fasteners Walker Evans Air Shocks Suspension Shock Oil Cooling Fins/Shroud Drive Shaft Bearings Jackshaft Bearings Skags (Wear Bars) Ski Saddle/Spindle Bolts Drive Chain Tension Hood Latches Rear Wheel Idler Bolts Idler Bolt Jam Nut Rear Suspension Pivot...

  • Page 78: Front Suspension

    The front suspension does not require lubrication. Rear Suspension Lubricate the suspension pivot shafts with Polaris Premium All Season Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 72 and before seasonal storage. When operating in heavy, wet snow conditions, lubricate every 500 miles (800 km).

  • Page 79: Throttle Cable

    MAINTENANCE Lubrication Driveshaft Bearing Fitting Inject grease into the fitting on the speed- ometer 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. Throttle Cable Lubricate the throttle cable lightly with grease or oil.

  • Page 80: Polaris Products

    500 miles (800 km), then every 1000 miles (1600 km) or seasonally. Polaris recommends the use of Polaris Synthetic Chaincase Lube. See page 110 for the part numbers of Polaris products. Oil Check 1. Position the vehicle on a level sur- face.

  • Page 81: Chaincase Oil

    MAINTENANCE Lubrication Chaincase Oil Oil Change 1. Position the vehicle on a level surface. 2. Remove the drain plug and drain the oil into a drain pan. Allow the oil to drain completely. 3. Clean off all metal shavings from the plug.

  • Page 82: Spark Plugs

    Spark Plugs 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. A hot exhaust system and engine can cause burns.
  • Page 83 Spark Plugs A new engine can cause temporary spark plug fouling due to the preser- vative added during the assembly process. Avoid prolonged idle speeds, which cause plug fouling and carbonization. Change the spark plugs every 2000-2500 miles (3200-4000 km). NOTICE: Using non-recommended spark plugs can result in serious engine damage.

  • Page 84: Intake Filters

    Intake Filters The intake foam filter limits snow ingestion into the intake system. When operating in loose powder snow, check the top of the foam filter periodically to remove any accumulation of snow. NOTICE: Operating the snowmobile with the intake filters removed may cause intake icing.

  • Page 85: Fuel Filter

    All fuel pump service must be performed by an authorized Polaris dealer. Do not attempt to service the fuel pump. Fuel Filter See your Polaris dealer for replacement of the fuel filter at the intervals outlined in the Periodic Maintenance Table beginning on page 72. Fuel Lines Inspect the fuel lines regularly for signs of deterioration or damage.

  • Page 86: Exhaust System

    Exhaust System Check the exhaust system for wear or damage at the intervals outlined in the Periodic Maintenance Table beginning on page 71. Hot exhaust system parts can cause burns. Allow adequate time for the exhaust system to cool. Never perform this procedure with the engine run- ning.

  • Page 87: Cooling System

    Use Premium 60/40 anti-freeze coolant, which is already premixed and ready to use. Do not dilute with water. Never exceed a 60% antifreeze/ 40% water mixture. See page 110 for the part numbers of Polaris prod- ucts. TIP: Never add tap water to the cooling system. Minerals cause deposits and may react adversely with the metals in the engine and cooling system.

  • Page 88: Flushing The Cooling System

    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.

  • Page 89: Bleeding The Cooling System

    MAINTENANCE Cooling System Bleeding the Cooling System 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.
  • Page 90 Cooling System Bleeding the Cooling System Bleed the cooling system at the intervals outlined in the Periodic Main- tenance Table beginning on page 72. Perform the bleeding procedure when the engine is cold. 1. Remove the pressure cap and fill the coolant bottle with properly mixed coolant to the maximum mark.

  • Page 91: Drive Chain Tension

    MAINTENANCE Drive Chain Tension Check drive chain tension weekly and before each long trip. To obtain correct chain tension: 1. Rotate the driven clutch counterclockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly.

  • Page 92: Hydraulic Brake Inspection

    Brakes n Hydraulic Brake Inspection Inspect the brake lever travel before each use of the snowmobile. See page 51. Brake pads must be replaced when the brake pad material becomes thin- ner than the backing plate, approximately 1/16" (1.5mm). A kit is avail- able for replacing brake pads.

  • Page 93: Brake Components

    1/16" (1.5mm). Excessive Lever Travel Hydraulic brakes are self- adjusting, but if excessive brake pad clearance develops (see page 89) bring the snow- mobile to an authorized Polaris dealer for inspection and adjustment. Bleed Screw Brake Disc Brake Line Brake Caliper...

  • Page 94: Brake Fluid

    NOTICE: Brake fluid will damage decals, paint and some plastics. Always wipe up spills immediately. Replace brake fluid at least every two years with Polaris DOT 4 high temperature brake fluid. See page 110 for the part numbers of Polaris products.

  • Page 95: Bleeding The Hydraulic Brake System

    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. 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.

  • Page 96: Removing Halogen Bulbs

    Lights Removing Halogen Bulbs Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fin- gers do touch the bulb, clean it with an alcohol-moistened towel. 1.

  • Page 97: Clutch System

    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.

  • Page 98: Drive Belt Installation

    Drive Belt Condition Belt width and length must match the center distance of the clutches and sheave width of the drive clutch. For this reason, Polaris recommends that only O.E.M. belts be used. Other belts may match the dimensions, but can drastically change the shift pattern, resulting in poor perfor- mance.

  • Page 99: Drive Belt Removal

    MAINTENANCE Clutch System Drive Belt Removal NOTICE: Do not attempt to remove the drive belt after operating in reverse. The snowmobile must be stopped after forward motion to prevent damage to components during belt removal. 1. Stop the engine after operating in a forward motion. TIP: For easier accessibility, make sure the clutch tool access hole is visible between the 11:00 and 2:00 positions of the clutch sheave.

  • Page 100: Drive Belt Adjustment

    Clutch System n Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge on the belt and apply downward pressure while measuring at point A. This measurement should be 1 1/4" (3.2 cm).

  • Page 101: Track Replacement

    Track Replacement When replacing the track, always install a track having the lug size rec- ommended for your model. See your Polaris dealer. NOTICE: Installing tracks with larger lugs on machines equipped with coolers will result in damage to the cooler or tunnel. Always install a track hav- ing the lug size recommended for your model.

  • Page 102: Track Lubrication

    Track Lubrication 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 lit- tle or no snow for lubrication.

  • Page 103: Track Tension

    Track Tension 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 run- ning. Track tension is critical for maximum efficiency and performance. Track tension controls the approach angle of the track to the rail beam in powder snow conditions.
  • Page 104 Track Tension If the track needs adjustment: 5. Loosen the rear idler shaft bolt. 6. Loosen the lock nuts. 7. Tighten or loosen the track adjusting screws as necessary to provide equal adjustment on both sides of the track. 8. Repeat the measurement on the other side of the track. TIP: Check more frequently when the snowmobile is new.

  • Page 105: Track Alignment/Condition

    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.
  • Page 106 MAINTENANCE Steering System Steering Inspection and Adjustment Check all steering system fasteners weekly and before a long ride. Tighten any loose fasteners.

  • Page 107: Ski Alignment

    Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski align- ment or camber adjustment. See your Polaris dealer. With the handlebars in a straight ahead position, and with vehicle weight compressing the suspension, measure from the straight edge of the skis at the center of the ski mounting bolt.

  • Page 108: Ski Skags

    Steering System n Ski Skags 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.

  • Page 109: Rail Slide Wear

    MAINTENANCE Steering System n Rail Slide Wear For ease of inspection, all Polaris rail slides have a wear limit indicator groove Minimum to indicate the minimum Thickness permissible slide thick- ness. Replace the rail slides if they are worn to the top of the groove at any point along their length.

  • Page 110: Cleaning And Preservation

    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 110 for the part numbers of Polaris prod- ucts. Cleaning and Preservation Proper storage starts with cleaning, washing, and waxing the hood, chassis, and plastic parts.

  • Page 111: Engine Protection

    MAINTENANCE Extended Storage Engine Protection Proper preparation of the engine and fuel system is vital to the preven- tion of rust and corrosion on precision engine parts during storage. Whenever the machine is stored for a period of more than 60 days, the engine must be fogged with fogging oil.

  • Page 112: Electrical Connections

    MAINTENANCE Extended Storage 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 machine should be supported off the ground to allow the track to hang freely.

  • Page 113: Polaris Products

    Part No. 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2-Cycle Engine Oil (qt.) 2871097 Premium 2-Cycle Engine Oil (gal.) 2871240 Premium 2-Cycle Engine Oil (2.5 gal.) 2871721 Premium Gold Synthetic 2-Cycle Engine Oil (qt.) 2871722 Premium Gold Synthetic 2-Cycle Engine Oil (gal.) 2872347 Premium Gold Synthetic 2-Cycle Engine Oil (2.5 gal.) 2874438...

  • Page 114: Troubleshooting

    Engine Troubleshooting Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Erratic engine oper- ating RPM during acceleration or load variations Harsh drive clutch engagement Drive belt turns over Machine fails to move Probable Cause Solution Drive clutch binding...
  • Page 115 Engine Troubleshooting Problem Noise in drive sys- Poor low RPM per- formance Engine doesn't turn Probable Cause Solution Broken drive clutch • SEE YOUR DEALER. components Bearing failure/ • SEE YOUR DEALER. chaincase, jackshaft, or front drive shaft Drive belt surface •...
  • Page 116 Engine Troubleshooting Problem Probable Cause Solution Engine turns but fails Faulty ignition to start No fuel to engine Engine lacks power Fouled or defective spark plug(s) Fuel filter (loss of high RPM power) Incorrect clutching Engine continually Faulty plug(s) backfires Fuel System Incorrect throttle freeplay or faulty...

  • Page 117: Suspension Troubleshooting

    Suspension Troubleshooting Problem Rear suspension bot- toms too easily Rides too stiff in rear Too much weight transfer when climb- Too little weight transfer when climb- Front end pushes Steering is heavy Machine darts from side to side Solution • Set static sag (see page 43). Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions.

  • Page 118: Drive Belt Troubleshooting

    Drive Belt Troubleshooting Causes Driving at low RPM Insufficient warm-up Towing at low RPM Riding with high RPM and slow speed (8000 RPM/10 MPH) Ice and snow build-up between track and tunnel Poor engine performance Loading machines onto trailers Clutch malfunction Slow, easy clutch engage- ment TROUBLESHOOTING...

  • Page 119: Warranty

    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.
  • Page 120 2. Polaris warranty will provide all dealerships with a monthly updated list of all stolen units to further monitor thefts. 3. Polaris warranty will aid in notifying the proper owner when a unit is recovered...

  • Page 121: Limited Warranty

    WARRANTY Limited Warranty Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM- ITED WARRANTY on all components of the Polaris snowmobile against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective parts that are covered by this warranty.

  • Page 122: Engine Oil

    How to Obtain Warranty Service If your snowmobile requires warranty service, you must take it to a Polaris dealer autho- rized 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).
  • Page 123 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.
  • Page 124 • Failures caused due to improper adjustments. • Failure due to unauthorized service. • Failures due to lack of service as required in the owner’s manual or Polaris updates. This includes off-season storage as listed in the owner’s manual. • Failure due to use of unauthorized parts or modifications.
  • Page 125 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.
  • Page 126 This snowmobile engine emissions limited warranty is in addition to the Polaris stan- dard limited warranty for snowmobiles. Polaris Industries Inc. warrants that at the time it is first purchased, this emissions-certi- fied snowmobile engine is designed, built and equipped so it conforms with U.S. Envi- ronmental Protection Agency regulations applicable to snowmobile emissions.
  • Page 127 Polaris dealer to perform any service that may be necessary for your snow- mobile. 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.

  • Page 128: Maintenance Log

    Present this section of your manual to your dealer each time your snow- mobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. DATE MILES (KM) 150 mi. (240 km) 500 mi.
  • Page 129 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)
  • Page 130 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)

  • Page 131: Index

    INDEX Accessories ....48 Apparel for Riding....12 Avalanches....15 Brake Components.
  • Page 132 Passenger Warning ....23 Polaris Products ....110 Pre-Ride Checklist ... 49-55 Pressure Cap Warning .
  • Page 133 INDEX Survival Preparation ... . 11 Suspension Adjustments, Front . . 39-41 Suspension Adjustments, Rear . . 42-45 Suspension Inspection ... 54 Suspension Lubrication, Front.

This manual is also suitable for:

700 rmk 155800 rmk shift600 rmk shift 2009700 rmk 155 2009800 rmk shift 2009800 rmk 155 2009 ... Show all

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