Instruction/ maintenance manual of the product 800 RMK Polaris
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Modifications to this snowmobile are not recommended and may result in voided warranty coverage. Please read the warranty section of this manual carefully .
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.
1 WELCOME Thank you for purchasing a POLA RIS 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.
2 The following are trademarks of POLARIS Industries Inc.: Copyright 2014 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication.
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.
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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.
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.
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.
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.
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.
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.
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.
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 .
14 SAFETY Operator Safety Driver Awareness Slow down when traveling near po les, 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.
15 SAFETY Operator Safety A valanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain: • T ake an avalanch e class • T ravel with experienced people • T ravel on designated trails • Make sure each person is equipped with a shovel, probe and avalanche beacon.
16 SAFETY Operator Safety Ice and Snow Build-up W ARNING! Ice and snow build-up may inte rf ere with the steering of your snowmobile, resulting in serious injury or death.
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.
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.
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.
20 SAFETY Operator Safety Windchill/T emperature Chart s The following information is provided to help you determine when temperatures become dangerous for riding.
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 .
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 .
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.
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 inj ury or death, read and understand all warnings and the Owner's Manual before op eration. If manual is missing, contact a POLARIS deal er for a replacement.
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.
26 FEA TURES 8 13 5 6 7 12 11 2 1 3 4 10 9 1. Nosepan 2. Skis 3. Front Bum per 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.
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.
28 FEA TURES 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.
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.
30 FEA TURES 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.
31 FEA TURES Fuel T ype Selection Whenever using ethanol, MTBE or other forms of oxygenated gasoline, the fuel type designation setting must be changed to “Eth” in the gauge. When using the recommended 91 non-ethanol gasoline, always select the “91-non” setting.
32 FEA TURES 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.
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 .
34 FEA TURES 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.
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.
36 FEA TURES 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.
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.
38 FEA TURES 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).
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.
40 FEA TURES 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 .
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.
42 FEA TURES 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.
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 will alternate between SECURE ON and ENTER CODE.
44 FEA TURES Instrument Cluster Rider Information Center Security System (Ignition Lock Syste m) Locking the System Wit h Y our Personal Security Code 1. Star t the engine and lock the parking brake. 2. Press and hold the MODE and SEL buttons for 3 seconds, then release.
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.
46 FEA TURES 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.
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.
48 FEA TURES 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.
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 In.
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.
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.
52 THE PERFECT FIT Suspension Adjustment s Fine-T uning Y our Suspension Set-Up The primary adjustment for overall ve hicle 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.
53 THE PERFECT FIT Suspension Adjustment s Shock Compression Da mping (RMK/ASSAUL T RMK) The primary adjustment for overall ve hicle 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.
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.
55 THE PERFECT FIT Handlebar Adjustment s Handlebar Position (if equipped) 1. Loosen the four bolts on the bottom of the adjust er block. If necessary , pry the blocks apart with a screwdriver . 2. Adjust the handlebar forward or rearward to the desired position.
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.
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.
58 PRE-RIDE INSPECTIONS Before St arting the Engine Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation.
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).
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.
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.
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.
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 urn the key to the ON position.
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.
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 .
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.
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).
68 OPERA T ION T r ack Wa rm-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.
69 OPERA TION Fuel Gasoline is highl y flammable and explosive u nder 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.
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.
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.
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.
73 OPERA TION Throttle Lever W ARNING! An improperly functioning throttle lever may cause erratic snowmobile behavior a nd loss of control, wh ich could result i n serious injury or death. If the thro ttle lever does not work properly , DO NOT start the engine.
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.
75 OPERA TION Electronic Reverse (PERC) Engaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Make sure the area behind your vehicle is clear . 3. Push the yellow reverse button on the left-hand control for one second, then releas e.
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.
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.
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.
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 133.
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 .
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 Condit.
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).
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.
84 MAINTENANCE Lubrication Rear Suspension Lubricate the suspension pivot shafts with POLARIS All Season Grease at the intervals outlined in the Periodic Maintenance T a ble beginning on page 80 and before seasonal storage. When operating in heavy , wet snow conditions, lubricate every 500 miles (800 km).
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.
86 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.
87 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 .
88 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.
89 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.
90 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 .
91 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 .
92 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.
93 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 .
94 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.
95 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.
96 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 injury or death.
97 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.
98 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 .
99 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.
100 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.
101 MAINTENANCE Clutch System Drive Belt Removal NOTICE: Do not attempt to remove the dri ve belt after operati ng in reverse. The snowmobile must be stop ped after forward moti on to prevent damage to components during belt removal.
102 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.
103 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 .
104 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.
105 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 104. If the track needs adjustment: 6. Loosen the rear idler shaft bolt.
106 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 the rear of the snowmobile with the track of f the ground.
107 MAINTENANCE S teering System Steering Inspection Each week, or before a long ride, check all steering system fasteners and tighten if necessary ..
108 MAINTENANCE S teering System Ski Alignment W ARNING! Improper ski alignment or adjust ment may cause loss o f 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 .
109 MAINTENANCE S teering System Ski Skags W ARNING! Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causi ng seri ous injury or death.
110 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.
111 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.
112 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.
113 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.
114 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.
115 MAINTENANCE Extended Storage Controls and Linkage Lubricate all bushings and cables as outlined in the Periodic Maintenance T able beginning on page 80.
116 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.
117 SPECIFICA T IONS 600 RMK 144 / 600 RMK 155 600 PRO RMK 155 Clutching Chart AL TIT UDE Meters (Feet) Drive Clutch Shift Wei gh t Drive Clutch Spri ng Driven Clutch Spr i ng Driven Helix Chaincase G.
118 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.
119 SPECIFICA T IONS 800 RMK 155 / 800 RMK ASSAUL T 155 800 PRO RMK Clutching Chart AL TITU DE Meters (Feet) Drive Clutch Shift Weig ht Drive Clutch Spr i ng Driven Clutch Spr in g Driven Helix Chainc.
120 POLARIS PRODUCTS Part No. Description Engine Lu bricants 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./.
121 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.
122 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.
123 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.
124 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.
125 W ARRANTY Service and W a rranty 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 .
126 W A RRANTY Limited W arranty POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a 12 MONTH LIMITED W ARRANTY on all co mponents of your POLARIS vehicle against defects in material o r workmansh ip.
127 W ARRANTY W arranty Coverage and Exclusions Limit ations of W arranties and Remedies This POLARIS Limited W arranty excludes any fa i lures that are not caused by a defect in material or workmanship. THIS W ARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN.
128 W A RRANTY W arranty Coverage and Exclusions Limit ations of W arranties and Remedies Lubricants and Fluids 1. Mixing oil brands or using non-recomm ended oil may cause engine damage.
129 W ARRANTY How to Obt ain W arranty Service If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer . When requesting warranty service you must present your copy of the W arranty Registration Form to the dealer . (THE COST OF TRANSPOR T A TION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY .
130 W A RRANTY Exported Product s EXCEPT WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W ARRANTY OR SER VICE BULLETIN COVERAGE ON THIS PRODU CT IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER’S AUTHORIZED LOCA TION. This policy does not apply to products that have received authorization for export from POLARIS.
131 W ARRANTY U.S.A. EP A Emissions Limited W arranty This Emissions Limi ted W arranty is in a ddition to the POLARIS standard Limited W arranty 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.
132 W A RRANTY U.S.A. EP A Emissions Limited W arranty The exclusive remedy for breach of this Limited W arranty shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products.
133 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.
134 MAINTENANCE LOG DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS.
135 INDEX A Accessori es . . . . . . . . . . . . . . . . . . . . 30 Air Pollutio n . . . . . . . . . . . . . . . . . . . . 6 Avalanches . . . . . . . . . . . . . . . . . . . . 15 B Battery . . . . . . . . . . . . . . . . . . 111-113 Charging . . . . .
136 INDEX F Fasteners, Hood and Side Panel. . . . 61 Fluid Change Chaincase . . . . . . . . . . . . . . . . . . 85 Coolant . . . . . . . . . . . . . . . . . . . . 90 Fluid Level Brake Fluid . . . . . . . . . . . . . . . . . 95 Chaincase . . . . . . . .
137 INDEX Q QUICKDRIVE Belt . . . . . . . . . . . . . 29 R Rail Slide We ar . . . . . . . . . . . . . . . . 110 Recoil Rope Inspection . . . . . . . . . . . 61 Registration, Warranty . . . . . . . . . . 126 Reverse Operation. . . . . . . . . . . . 74-75 Reverse Warning.
For your nearest Polaris dealer , call 1-800-POLARIS (765-2747) or visit www .polaris.com Polaris Industries Inc., 2100 Hwy . 55, Medina, MN 55340 Part No.
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