Polaris 600 PRO RMK, Owner'S Manual

Page 1: ...t recommended and may result in voided warranty coverage Please read the warranty section of this manual carefully IMPORTANT NOTICE TO OWNER Snowmobile Owner s Manual for Maintenance and Safety 600 RMK 600 PRO RMK 800 RMK 800 PRO RMK 800 RMK ASSAULT ...

Page 2: ...ons in this manual and on all product labels Failure to follow the safety precautions could result in serious injury or death WARNING The engine exhaust from this product contains chemicals known to the State of California to cause cancer birth defects or other reproductive harm ...

Page 3: ...d recreational vehicles manufactured in the world today Many years of experience have gone into the engineering design and development of your POLARIS vehicle making it the finest machine we ve ever produced For safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but infor...

Page 4: ...he actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for reference use only No liability can be accepted for omissions or inaccuracies Any reprinting or reuse of the depictions and or procedures contained within whether whole or in part is expressly prohibited The original instructions for this vehicle are in English Othe...

Page 5: ... and features The Perfect Fit 50 This section includes suspension set up information and explains how to make additional suspension adjustments for the perfect riding experience Pre Ride Inspections 56 This section explains procedures that must be performed before riding Operation 63 This section explains proper engine break in operation of features and general operating procedures Maintenance 78 ...

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Page 7: ...are inspected by your dealer at specific mileage intervals You and your dealer must complete the registration form included with your snowmobile and forward it to us This completed form is necessary to ensure warranty coverage Protect and preserve your right to ride by joining your local trail riding clubs When teaching inexperienced operators to ride set up a predetermined course for practice Mak...

Page 8: ...hat snowmobiles conform to prescribed sound levels POLARIS snowmobiles are engineered to conform to these SAE standards Our muffler systems are designed to reduce noise levels and must not be altered or removed The sound of your snowmobile may not be welcome to non snowmobilers so you have a responsibility to operate your snowmobile with concern for others We do our part by manufacturing quieter m...

Page 9: ...g a POLARIS key blank with one of your existing keys so if both keys are lost the ignition switch must be replaced Vehicle Model Number ___________________________________________________ Tunnel VIN right side of tunnel ____________________________________________ Engine Serial Number on recoil housing _____________________________________ Key Number _______________________________________________...

Page 10: ...ous situation that if not avoided will result in death or serious injury WARNING A WARNING indicates a hazardous situation that if not avoided could result in death or serious injury CAUTION A CAUTION indicates a hazardous situation that if not avoided could result in minor or moderate injury NOTICE A NOTICE indicates a situation that could result in property damage The Prohibition Safety Sign ind...

Page 11: ...s in excellent operating condition at all times Always check major and vital safety components before every ride All POLARIS snowmobiles are designed and tested to provide safe operation when used as directed Failure of critical machine components may result from operation with any modifications especially those that increase speed or power DO NOT MODIFY YOUR MACHINE The snowmobile may become aero...

Page 12: ... off the ignition open the side panels or hood make the adjustment secure shields and guards secure the side panels and hood and then restart the engine to check its operation WARNING Serious injury can occur if fingers or clothing contact the moving parts of an engine Always stop the engine before attempting adjustments Riding Position Operating a snowmobile requires skill and balance for proper ...

Page 13: ...er will also be displayed on the label Eye Protection Do not depend on eyeglasses or sunglasses for eye protection Whenever riding a POLARIS vehicle always wear shatterproof goggles or use a shatterproof helmet face shield POLARIS recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Clothing Be pre...

Page 14: ...e If it isn t possible to ride with others and you must travel into remote areas always carry survival equipment that s appropriate to the conditions you may encounter Such equipment may include but is not limited to extra clothing a sleeping bag a flashlight food and water a signaling mirror a means of building a fire and a two way radio or cellular telephone Always carry the owner s manual on yo...

Page 15: ... and speed limits Always be alert and pay attention to the trail ahead If your speed is 40 MPH 64 km h your snowmobile is traveling about 60 feet 18 m per second If you look back for only two seconds your snowmobile will travel about 120 feet 36 m If your speed is 60 MPH 96 km h your snowmobile will travel about 180 feet 55 m in two seconds Traveling at night requires extra caution Check headlight...

Page 16: ...elf a way out Variances in snow depth and or water currents may result in uneven ice thickness You may drown if you break through the ice Never travel on frozen bodies of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the snowmobile you and your cargo together with any other vehicles in your party Always check with local authoritie...

Page 17: ... snow is connected You may be riding on a flat slope or snow covered road but if the snowpack above is unstable enough you can trigger an avalanche on a steeper slope above you Always be aware of snow conditions above you as you travel in mountainous terrain Before riding in mountainous terrain call or log on to your local avalanche advisory to get current weather and snow stability information Fo...

Page 18: ...erating on slippery surfaces Inadequate Snow Conditions Since snow provides the only lubrication for the power slide suspension and on liquid cooled models cooling for the engine adequate snow cover is a requirement for operation of your snowmobile NOTICE Driving in too little snow will result in excessive wear and damage to the slide rail track and or engine WARNING Inadequate cooling and lubrica...

Page 19: ... causing serious injury or death Use caution and good judgement when driving in hilly terrain Use extra caution when operating in hilly terrain If climbing a hill is unavoidable keep your weight low and forward If you must cross the face of a slope keep your weight on the uphill side of the snowmobile to maintain proper balance and avoid possible roll over Slow down when reaching the crest of a hi...

Page 20: ... complex mechanism that rotates at high speeds Each clutch is dynamically balanced before installation Any tampering may disrupt this precision balancing and create an unstable condition Cold Weather Drive Away Whenever your snowmobile has been parked for a length of time especially overnight always make sure the skis and track are loosened from ice and snow before attempting to drive Apply the th...

Page 21: ...ell as yours make sure they take a snowmobile safety course Everyone can benefit from the course Don t jump your snowmobile over large drifts or similar terrain Jumping may injure your back because of spinal compression that could occur when the snowmobile impacts the ground The seat and suspension of your snowmobile have been designed to provide protection under normal riding conditions Your snow...

Page 22: ...3 50 26 19 12 4 3 10 17 24 31 38 45 52 60 67 74 81 88 95 55 25 18 11 4 3 11 18 25 32 39 46 54 61 68 75 82 89 97 60 25 17 10 3 4 11 19 26 33 40 48 55 62 69 76 84 91 98 Frostbite in 30 min 10 min 5 min Wind Speed in Km h Actual Thermometer Reading C 5 2 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 Equivalent Temperature C Calm 5 2 1 4 7 10 13 16 19 22 25 28 31 34 37 40 43 46 8 3 0 4 7 11 14 18 22 25...

Page 23: ...rchase a replacement Replacement safety labels are provided by POLARIS at no charge The part number is printed on the label Clutch Warning This warning label is found on the oil bottle WARNING Do not operate engine with hood or side panels open Do not attempt adjustment with engine running Do not operate engine with the clutch guard removed Never run engine with drive belt removed Never service cl...

Page 24: ...w the windshield WARNING Reverse operation even at low speeds can cause loss of control resulting in serious injury or death To avoid loss of control always Look behind before and while backing up Avoid sharp turns Shift to or from reverse only when stopped Apply throttle slowly NOTE For more information see Owner s Manual If electric reverse Machine stopped and engine at idle push yellow button o...

Page 25: ...from seat back may result in severe injury or death Hot Surface Warning The hot surface warning is on the rear center of the tunnel WARNING Hot Surface Do Not Touch Burns may result Entire top of tunnel may be hot Install only accessories specifically approved for this model by POLARIS Do not place clothing bags or cargo on tunnel Do not cover this label Track Warning Hot Surface Warning ...

Page 26: ...unfamiliar terrain Excessive speed especially at night or with limited visibility can result in insufficient time for you to react to terrain changes to avoid unexpected obstacles or to stop safely Never consume alcohol or drugs before or while operating this vehicle In an emergency push down the Auxiliary Shut Off Switch located on the top of the throttle control assembly to stop the engine Then ...

Page 27: ...ain vehicle control on ice or hard packed surfaces you should have a proper balance of ski carbides to track studs See Owner s Manual for proper use of traction products Repeated stops from high speed may cause fading or sudden loss of braking ability Parking brake may relax when used for long periods Do not leave brake engaged for more than five minutes Before starting engine check throttle brake...

Page 28: ...2 11 2 1 3 4 10 9 1 Nosepan 2 Skis 3 Front Bumper 4 Hood 5 Headlight 6 Windshield accessory 7 Handlebar 8 Operator Seat 9 Taillight 10 Rear Bumper 11 Snow Flap 12 Suspension 13 Track 14 Side Panel 15 Side Panel Fasteners 15 14 ...

Page 29: ...ine Stop Switch 5 Throttle Control 6 Recoil Starter Handle 7 Brake Lever 8 Parking Brake Lock 9 Handlebar Grip Warmer Switch 10 Thumbwarmer Switch 11 Electronic Reverse Button 12 Mode Switch 13 Headlight Dimmer Switch 1 3 4 5 6 2 12 11 13 8 9 10 7 PRO RMK ASSAULT RMK 12 13 9 ...

Page 30: ... the rear of the tunnel Cargo may be stowed only under the seat and as far forward as possible immediately behind the seat brace The maximum weight capacity for the tunnel is 15 lbs 7 kg Do not exceed the weight limit Adjustable Headlights Move the headlight adjuster to the left to adjust the headlight beam upward Move the adjuster to the right to adjust the beam downward Storage Bag Up Down ...

Page 31: ...al tools are required to remove and install the QUICKDRIVE belt Please see your POLARIS dealer for this service or refer to the instructions provided with the purchase of a new belt Belt Handling Store a new belt in original packaging Remove only when ready for installation Avoid belt contact with solvents oils or chemical cleaners Do not crimp or bend the belt to a diameter less than the upper sp...

Page 32: ...wmobile Use of unapproved parts and accessories may result in Non compliance with government industry requirements Voiding of warranty Injury to self or others This applies but is not limited to the following areas brakes clutches fuel systems and exhaust systems Exhaust systems are critical safety areas that must use approved POLARIS parts Please see your POLARIS dealer for service ...

Page 33: ...your fuel purchase use the Eth setting as a safeguard Use the following procedure to change the fuel type designation in the gauge Refer to the fuel type selection label located inside the left side panel 1 Start the engine 2 Lock the parking brake 3 Press and release the SELECT button or SET switch until FUEL is displayed in the lower section of the gauge 4 Press and hold the SELECT button or SET...

Page 34: ...cases this is temporary and the operator does not need to take any action The engine will return to its normal performance automatically If severe detonation occurs the check engine light will begin to flash steadily and the gauge indicator will read dET see illustration The engine will enter a limp home mode and RPM will be limited to 6500 RPM The engine will remain in this mode until it is shut ...

Page 35: ...l not move when throttle is applied If you wish to use this system see page 41 of the Instrument Cluster section for security system activation and operating instructions Cause of DET Activation Solution Poor quality fuel Replace with higher quality fuel Incorrect ethanol non ethanol fuel resistor installed Verify correct fuel resistor for fuel type in tank Low fuel no fuel in tank Refuel with rec...

Page 36: ...andlebar or console NOTICE Certain products will damage the lens and other plastic surfaces Do not use alcohol to clean the instrument cluster Immediately clean off any gasoline that splashes on the instrument cluster Rider Information Center Check Engine Indicator High Beam Indicator Low Oil Indicator Over Tem perature Indi cator Park Brake Indicator Reverse Indicator MODE Button SELECT Button Mo...

Page 37: ... indicator flashes continued operation could result in serious engine damage Stop the engine immediately Low Oil Indicator The low oil indicator light may flicker at times due to oil movement in the bottle but when the light comes on and remains on add the recommended oil before further operation See page 71 High Beam Indicator The high beam indicator illuminates when the lights are set to high be...

Page 38: ...ettable trip meters 2 total engine hours of operation fuel level engine temperature and diagnostic display mode Setting changes must be made with the engine running or with the vehicle powered by an external DC power supply connector The information center is set to display standard units of measurement for distance and temperature To change to metric units see page 40 2 3 6 4 5 1 ...

Page 39: ... When the last segment clears a low fuel warning is activated All segments including the fuel icon will flash Refuel immediately Tip If the fuel icon fails to display an open or short circuit has occurred in the fuel sensor circuit See your dealer 4 Odometer Engine Hour Display This area displays the odometer Trip A Trip B and engine hours To change the display see page 39 5 Battery Power This ind...

Page 40: ...isplays first make sure the information display area is set to display either engine speed or vehicle speed 2 Press and hold the mode button on the instrument cluster or the mode switch on the left handlebar for three seconds Information Display Area This area displays either engine speed or vehicle speed whichever is not displayed in the speed display engine temperature and maximum vehicle speed ...

Page 41: ... To reset a trip meter press and hold the SELECT button or the SET switch until the meter resets to zero Playback Function The playback function allows the rider to record and play back engine speed vehicle speed and throttle position sensor information for up to three minutes 1 To begin recording simultaneously press and hold the MODE and SELECT buttons on the instrument cluster for three seconds...

Page 42: ...s are changed The new settings will remain until changed by the operator Change Method 1 1 Press and release the MODE button or MODE switch until engine temperature displays 2 Press and hold the MODE button or MODE switch until the units change Change Method 2 1 Press and release the SELECT button or SET switch until the odometer displays 2 Press and hold the SELECT button or SET switch until the ...

Page 43: ...feature activated you can lock the ignition to prevent unauthorized use when leaving the snowmobile unattended A locked system will limit engine speed to 3000 RPM which prevents clutch engagement and the snowmobile will not move when throttle is applied If you wish to use this feature you must complete all four tasks on the following pages to have your system activated and to change the security c...

Page 44: ...ns for 3 seconds then release SECURE OFF should be displayed If not repeat this step 3 Wait until ENTER CODE displays then press and release SEL to advance the digit When 0 is displayed press and release MODE to accept the digit TIP If the ENTER CODE screen exits due to inactivity repeat step 2 4 Press and release SEL to advance the second digit When 0 is displayed press and release MODE to accept...

Page 45: ...m is now unlocked 5 You must now enter a new security code Proceed immediately to TASK 4 TASK 4 Enter Your New Security Code 1 Immediately after locking and unlocking the system and while SECURE OFF is displayed press and release the MODE button to bring up the ENTER CODE screen 2 When ENTER CODE displays use the SEL and MODE buttons to select and accept each digit of a new personal security code ...

Page 46: ...igit of your security code is displayed press and release MODE to accept the digit TIP If the ENTER CODE screen exits due to inactivity repeat step 2 4 Continue to use SEL and MODE to select and accept the remaining two digits of the code 5 After accepting the third digit view the display screen SECURE ON displays if the system locks Engine speed is now limited and the snowmobile cannot be driven ...

Page 47: ...hen the first digit of your security code is displayed press and release MODE to accept the digit TIP When the system is locked and engine temperature is above 120 F 49 C the correct password must be entered within 60 seconds or the engine will shut down 2 Continue to use SEL and MODE to select and accept the remaining two digits of the code 3 After accepting the third digit view the display scree...

Page 48: ...stem Access Quick Reference Now that you have become familiar with the procedure for locking and unlocking the system use the chart below as a quick reference Security System Access Quick Reference Chart Action Result Start engine Lock parking brake Press and hold both MODE SELECT SEL Displays ENTER CODE to lock the system Press SELECT SEL Advances a digit on the ENTER CODE screen Press MODE Accep...

Page 49: ...tive codes 1 Do not stop the engine 2 With the brake engaged press and release the SELECT button or SET switch to toggle to the diagnostic display mode When a code is active the diagnostic display mode will appear immediately following the engine hour display TIP When the diagnostic mode is displayed the check engine warning indicator will begin to flash 3 A set of two numbers will appear in the d...

Page 50: ...to the electronic control unit is shorted to a wire at battery voltage Diagnostic Codes Component Condition SPN FMI Throttle Position Sensor Voltage Too High 51 3 Voltage Too Low 4 Abnormal Rate of Change 10 Vehicle Speed Sensor Data Erratic Intermittent or Missing 84 2 Intake Air Temperature Sensor Voltage Too High 105 3 Voltage Too Low 4 Barometric Pressure Sensor Voltage Too High 108 3 Voltage ...

Page 51: ...AG Maximum Detonation Correction Limit Reached 1352 0 Knock Above Critical Level 16 Knock Level Cylinder 2 PTO Maximum Detonation Correction Limit Reached 1353 0 Knock Above Critical Level 16 Sensor Supply Voltage 1 TPS TMAP Sensor Power Voltage Too Low 3509 4 Sensor Supply Voltage 2 Ground Speed Sensor Voltage Too Low 3510 4 ECU Output Supply Voltage 2 Injection Supply PWR Voltage Too High 3598 3...

Page 52: ...on NOTICE Never adjust spring preload to an installed length longer than the maximum or shorter than the minimum lengths in the following chart Damage to the suspension could result Never exceed one inch 2 54 cm of preload beyond the factory settings When decreasing preload make sure at least two turns of preload are holding the retainer against the spring Spring Type Maximum Installed Length Mini...

Page 53: ...ot sufficient for riders over 300 lbs 136 kg optional heavy springs are available Please see your POLARIS dealer Initial RTSS Preload Settings Measure spring length with suspension off the ground Rider Weight Model Installed Length For Factory Installed Springs Under 160 lbs Under 73 kg RMK PRO RMK 10 3 4 27 3 cm ASSAULT RMK 10 7 8 27 6 cm 160 220 lbs 73 100 kg RMK ASSAULT RMK 10 1 4 26 cm PRO RMK...

Page 54: ... the snowmobile more flickable although it may hinder climbing performance For less ski lift transfer increase spring preload by reducing the installed length Rotate the spring 1 2 full turns clockwise when viewed from bottom This will improve climbing ability and rider control To control the overall balance of the vehicle use the following guideline More rear track shock spring preload increases ...

Page 55: ...he desired ride quality is achieved ASSAULT RMK Damping Compression damping can be adjusted at the front suspension and at the rear track shock Make adjustments in 2 click increments then test ride When adjusting the front suspension always adjust both clickers equally To stop bottoming of the front or rear suspension stiffer ride rotate the clicker s clockwise two clicks as viewed from the top of...

Page 56: ...usting the front suspension be sure the springs on both sides of the vehicle are at the same adjustment Always perform shock spring preload adjustments with the weight of the vehicle removed from the shock and with the shock at full extension NOTICE Never exceed one inch 2 54 cm of preload beyond the factory settings When decreasing preload make sure at least two turns of preload are holding the r...

Page 57: ...bars brake lever and throttle lever operate smoothly and do not hit the gas tank windshield or any other part of the machine when turned fully to the left or right If necessary loosen the set screws for the left and right controls rotate the controls slightly then tighten the set screws to the proper torque NOTICE Do not stretch wires while adjusting the controls Stretching the wires could damage ...

Page 58: ...ant Level 91 Chaincase Oil Level 85 Injection Oil Level 71 Parking Brake Lock Brake Lever Brake System 59 60 96 Auxiliary Shut Off Switch Engine Stop Switch 62 Ignition Switch 62 Headlight Taillight Brakelight 62 Suspension Mounting Bolts 57 Skags Wear Bars 111 Ski Saddle and Spindle Bolts 57 Hood and Side Panel Fasteners 83 Throttle Lever Safety Switch 72 73 Rear Wheel Idler Bolts 107 Tether Swit...

Page 59: ...ms Check the following items on a weekly basis or before any long trip Item See Page Check suspension mounting bolts for tightness Check rear idler wheel bolts for tightness 107 Check rear idler adjusting bolt locknuts for tightness Check front torque arm limiter strap condition Check rail slide condition 112 Check track tension 106 Check ski runner skag condition 111 Check ski spindle bolts for t...

Page 60: ...al Read the Owner s Manual completely and refer to it often The manual is your guide to safe and enjoyable snowmobiling experience Throttle Lever The throttle and brake are the primary controls of your snowmobile Always make sure both are functioning properly Squeeze the throttle lever to make sure it compresses evenly and smoothly When released the lever should immediately return to the idle posi...

Page 61: ...ates low brake fluid level or air in the hydraulic system Refer to the brake bleeding information on page 98 or see your dealer for service Lever Feel If the brake lever feels spongy when squeezed check the brake fluid level and condition Add fluid as needed See page 97 WARNING Continued use of spongy brakes may cause a complete loss of brakes which could result in serious injury or death Always h...

Page 62: ...e Do not force the lock or it may break The parking brake light on the gauge will light up if the parking brake lever lock is set while the engine is running It will also be lit when the service brake is in use If the parking brake light does not come on when the parking brake or service brake is in use have it serviced by your dealer Lock Release To release the lock squeeze the brake lever tightl...

Page 63: ...NG Use of traction products such as studs increases the possibility of track damage and or failure Driving at high speeds for extended periods of time in marginal lubrication could severely damage track rods break track edges and cause other track damage Examples of marginal lubrication would include frozen bodies of water without snow cover icy trails and no snow conditions Hood and Side Panel Fa...

Page 64: ... switch down to stop the engine Pull it up to allow restarting Ignition Switch Make sure the engine stops when the ignition switch is turned to OFF Tether Switch if equipped If your snowmobile has a tether switch remove the tether from the switch to make sure the engine stops immediately Lighting Check the headlight high and low beam taillight and brake light Replace burned out lamps before operat...

Page 65: ...en pull abruptly to crank the engine TIP Don t pull the starter rope to the fully extended position and don t allow it to snap back into the housing Damage may result 5 If the engine does not start after several attempts slightly depress the throttle no more than 1 4 inch 2 54 cm open while cranking the engine When the engine starts immediately release the throttle CAUTION To avoid injury and or e...

Page 66: ...procedure If the engine fails to start using the normal procedure 1 Push the engine stop switch down to the OFF position 2 Turn the key to the OFF position 3 With both switches OFF squeeze and hold the throttle in the wide open position 4 Crank the engine several times to clear the engine 5 Release the throttle 6 Restart the engine using the normal starting procedure ...

Page 67: ...RIS products Never mix brands of oil Serious chemical reactions can cause injection system blockage resulting in serious engine damage Oils may also be incompatible and the result could be sludge formation filter blockage and reduced cold weather flow rates All POLARIS oils are compatible with each other Initial Fuel Premix Always premix fuel in 5 gallon 19 liter increments in a separate fuel cont...

Page 68: ... damage NOTICE Use of any lubricants other than those recommended by POLARIS may cause serious engine damage We recommend the use of POLARIS lubricants for your vehicle Drive with extra caution during the break in period Perform regular checks on fluid levels lines and all other important areas of the snowmobile Oil Injection System Always check and fill the oil bottle when refueling See page 71 N...

Page 69: ...reak in period the sound will become similar to that of a traditional chaincase Improper track tension can result in track ratcheting which will affect QUICKDRIVE belt durability Always maintain proper track tension See page 106 During the break in period this belt sheds a fiber type material in and around the drive system Use a dry shop towel to clean the residue Stop occasionally and allow the s...

Page 70: ...e stand to securely support the rear of the snowmobile at the rear bumper The track should be about 4 inches 10 cm off the ground 2 Start the engine and allow it to warm up two to three minutes 3 Depress the throttle abruptly and allow the track to rotate several revolutions TIP It will take longer to warm up the track sufficiently during colder outdoor temperatures 4 Release the throttle apply th...

Page 71: ... in or near the area where refueling is performed or where gasoline is stored If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing Never start the engine or let it run in an enclosed area Engine exhaust fumes are poisonous and can cause loss of consciousness or death in a short time The engine exhaust from this product contains chemicals known...

Page 72: ...ded Prolonged exposure to petroleum based products may damage paint Always protect painted surfaces when handling fuel Fuel System Deicers If you use non ethanol fuel sometimes labeled non oxygenated POLARIS recommends the regular use of isopropyl based fuel system deicer Add one to two ounces per gallon 8 16 ml per liter of gasoline to prevent damage resulting from fuel system icing Never use dei...

Page 73: ...indicator light comes on 2 Open the left side panel 3 View the oil level in the oil bottle 4 Add oil as needed before operating NOTICE Operating the snowmobile without adequate engine lubrication can result in serious engine damage Always check the oil level when refueling Add oil as needed The oil bottle cap is vented to allow proper oil flow See your POLARIS dealer for recommended replacement pa...

Page 74: ...y switch can result in serious injury or death in the event of an accident If the throttle safety switch does not shut off the engine during a carburetor throttle system malfunction immediately push down the engine stop switch Do not start the engine again until the malfunction has been corrected by your dealer Test the throttle safety switch system daily before operation 1 Sit on the seat 2 Start...

Page 75: ...f the throttle lever operates properly turn the ignition switch on and go through normal starting procedures 5 If the engine doesn t start take the snowmobile to an authorized POLARIS dealer for service Excessive freeplay in the throttle cable may cause the safety switch to activate preventing the engine from starting If this occurs return the snowmobile to an authorized POLARIS dealer for service...

Page 76: ...dle speed Shift to or from reverse only when the snowmobile is stopped and when engine speed is at idle Look behind the vehicle before and while backing Avoid sharp turns Apply throttle slowly Electronic reverse will activate only if the engine RPM is below 4000 NOTICE Engaging the starter when the engine is running WILL result in serious engine damage especially if the transmission is in reverse ...

Page 77: ...ransmission is in reverse The maximum engine RPM will be 6000 when in reverse TIP If the engine stops running the snowmobile will be in forward gear when it s restarted Disengaging Reverse 1 Stop the snowmobile and leave the engine idling NOTICE Engaging the starter when the engine is running WILL result in serious engine damage especially if the transmission is in reverse Never engage the starter...

Page 78: ...y See page 72 for more information about the engine stop switch and throttle safety switch SYSTEM WHAT IT DOES Ignition Switch Interrupts ignition circuit Brake Slows jackshaft Engine Stop Switch Interrupts ignition circuit Throttle Safety Switch Interrupts ignition circuit Tether Switch Option Interrupts ignition circuit ...

Page 79: ...e tow hitch on the snowmobile should be used If passengers are to be towed on a toboggan or sled make sure the pole is at least four feet 1 2 meters long to prevent any possibility of contact between the snowmobile s track and a person riding in the towed object WARNING Braking distances increase when towing loads Slow down to maintain control of the snowmobile If the snowmobile becomes inoperable...

Page 80: ...ne with a minimum octane level of 87 R M 2 If your snowmobile is equipped with a check engine light and it comes on you must take your snowmobile to a qualified dealer for diagnostic service Specifications and adjustments for engine tune ups are located in the Service Manual which is available to your qualified service technician Reverse if equipped must not be engaged during engine tune ups Owner...

Page 81: ...ervals All necessary replacement parts and labor incurred with the exception of authorized warranty repairs become the responsibility of the registered owner If during the course of the warranty period part failures occur as a result of owner neglect in performing recommended regular maintenance the cost of repairs are the responsibility of the owner Personal safety is critical when attempting to ...

Page 82: ...See Page Frequency 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 3200 km Pre Season CLUTCH Clutch Alignment Offset without belt 100 I I I Drive Belt Condition 101 I I I I QUICKDRIVE Belt 101 I I I R I Clutches 100 C C C Belt Tension I I I I Clutch Sheaves 100 I I I I ENGINE COOLING Engine Mounts I I I I Recoil Rope I I I I Cylinder Head Bolts I I I Cylinder Base Nuts I I I Ignition Timing BT...

Page 83: ...I I I Brake System 59 96 I Brake Fluid 97 I FUEL MANAGEMENT Idle RPM I I I Throttle Lever 73 I I I I I Oil Pump Lever synchronize I I I Throttle Position Sensor I I I Fuel Lines 87 I I I I Fuel Filter 87 R Every 2000 mi 3200 km or Every 2 years Oil Filter 90 R Oil Lines 90 I I I Air Box I I I I I ELECTRICAL Auxiliary Shut Off Switch 62 I I I I I Throttle Safety Switch 72 I I I I I Ignition Switch ...

Page 84: ...Steering Fasteners I I I I C Suspension Shock Oil R Cooling Fins and Shroud I I I I Drive Shaft Bearing 86 L L L I Skags Wear Bars 111 I I I I I Ski Saddle Spindle Bolts I I I I I Drive Chain Tension 95 I I I I I Hood and Side Panel Fasteners 83 I I I I I Rear Wheel Idler Bolts 107 I I I I I Idler Bolt Jam Nut 107 I I I I I Camber Alignment I I I Handlebar Centering I Tether Switch and Strap 62 I ...

Page 85: ...place before starting the engine To open a side panel rotate the two 1 4 turn fasteners at the upper edges of the side panel Release the side panel strap at the lower edge of the panel To remove an open side panel pull the panel outward to release the tabs at the lower edge of the panel Removing the hood is not recommended Any service requiring the removal of the hood should be performed by an aut...

Page 86: ...ned in the Periodic Maintenance Table beginning on page 80 and before seasonal storage When operating in heavy wet snow conditions lubricate every 500 miles 800 km Lack of lubrication will adversely affect your ride and the life of the suspension For more information about suspension lubrication and adjustments see your POLARIS dealer ...

Page 87: ...n cloth 5 Reinstall the fill plug Torque to 6 10 ft lbs 8 13 Nm Oil Change 1 Position the vehicle on a level surface 2 Place a drain pan under the drain plug Remove the drain plug Allow the oil to drain completely 3 Clean off all metal shavings from the plug TIP The sealing surfaces on the drain plug and the oil tank should be clean and free of burrs nicks or scratches 4 Reinstall the drain plug T...

Page 88: ...aft Bearing RMK ASSAULT 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 ...

Page 89: ...ty fuel will shorten the life of the fuel filter and result in poor engine performance Always store fuel in clean fuel containers If low fuel pressure or reduced engine performance occurs between the recommended fuel filter service intervals the filter may need replacement See your dealer Inspect the fuel lines regularly for signs of deterioration or damage Always check fuel line condition after p...

Page 90: ...e spark plugs at the intervals outlined in the Periodic Maintenance Table beginning on page 79 Use recommended spark plugs with the proper gap Use only resistor type spark plugs Torque spark plugs to 18 22 ft lbs 24 30 Nm Always carry spare spark plugs NOTICE Using non recommended spark plugs can result in serious engine damage A spark plug with a heat range too high will always cause engine damag...

Page 91: ...4 Reverse the procedure for spark plug installation Torque to specification 5 Reinstall the spark plug cap Spark Plug Condition Normal Plug The normal insulator tip is gray tan or light brown There will be few combustion deposits The electrodes are not burned or eroded This indicates the proper type and heat range for the engine and the service TIP The tip should not be white A white insulator tip...

Page 92: ...tion 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 ...

Page 93: ... See page 122 for POLARIS products Never add tap water to the cooling system Minerals cause deposits and may react adversely with the metals in the engine and cooling system Coolant Level The engine coolant level is controlled by the recovery system The recovery system components are Coolant bottle overflow tank Pressure cap Connecting hoses Always maintain the coolant level at or slightly above t...

Page 94: ...gine frequently to allow it to cool down Flashing Indicator If the indicator flashes continued operation could result in serious engine damage The system will automatically reduce engine power and create a misfire condition Stop the engine immediately Allow the engine to cool down If engine overheating seems to be caused by something other than poor cooling conditions see your dealer for service F...

Page 95: ...t this time 5 Remove the bleed screw from the water outlet manifold and or the thermostat housing Allow the coolant to bleed through the system until it runs out the bleed holes Reinstall the bleed screw into the manifold 6 Add coolant to the coolant bottle to the maximum mark 7 Reinstall the side panel Always ensure that the hood and side panels are securely in place before starting the engine 8 ...

Page 96: ...ecting CAUTION Hot exhaust system parts can cause burns Allow adequate time for the exhaust system to cool Never perform this procedure with the engine running 1 Open the side panels and remove the hood See page 83 2 Inspect the muffler and pipes for cracks or damage 3 Check for weak or missing retaining springs or damper support grommets 4 Check for loose clamps on the pipe covers ...

Page 97: ...slack to the tensioner side Lock the brake lever lock or have an assistant hold the brake lever firmly 3 Loosen the adjuster bolt jam nut 4 Finger tighten the adjuster bolt until it can no longer be adjusted by hand then back off 1 4 turn 5 Tighten the jam nut while holding the adjuster bolt Torque to 21 ft lbs 28 Nm 6 Reinstall the side panels 7 Release the brake lever lock Jam Nut Adjuster Bolt ...

Page 98: ...d that brake lever travel is not excessive Always replace brake pads when the brake pad material becomes thinner than the backing plate approximately 1 16 inch or 1 5 mm Brake Components 1 Brake Caliper 2 Brake Disc 3 Brake Pad Material Replace when thickness is less than 1 16 inch or 1 5 mm 4 Anti rattle springs come with brake pad kit Excessive Lever Travel Hydraulic brakes are self adjusting bu...

Page 99: ...ake fluid always discard any unused portion Never store or use a partial bottle Brake fluid is hygroscopic meaning it rapidly absorbs moisture from the air The moisture causes the boiling temperature of the brake fluid to drop which can lead to early brake fade and the possibility of accident or serious injury WARNING Keep the master cylinder cover free of dirt and debris The vent slits allow for ...

Page 100: ...2 Fill the master cylinder reservoir to between the MIN and MAX marks or 1 4 5 16 inch 6 8 cm below the lip of the reservoir opening Reinstall the gasket and cover 3 Slip a rubber tube over the ball of the bleeder valve and direct the flow of fluid into an approved container 4 Squeeze the brake lever a full stroke Then unscrew the bleeder valve 3 4 of a turn to release air 5 Close the bleeder valv...

Page 101: ...g the headlight assembly 2 Remove the wire harness connector from the back of the headlight 3 Grasp the bulb housing and turn it counter clockwise to remove the bulb 4 Apply dielectric grease to the socket and install the new bulb Rotate the bulb 1 4 turn clockwise to secure it 5 Reinstall the connector to the back of the headlight 6 Secure the foam shield Taillight Brake Light Replacement The tai...

Page 102: ... repairs have been made All clutch maintenance and repairs must be performed by an authorized POLARIS dealer Any unauthorized modifications to clutches such as adding or removing weights will void the warranty NOTICE The bushings in the weights and rollers of POLARIS clutches are made of a material that may be damaged if lubricated Do not lubricate clutch bushings Clutch Alignment Offset Clutch al...

Page 103: ...temperature Reinstall it before starting the snowmobile QUICKDRIVE Belt Condition PRO RMK Periodically check the condition of the QUICKDRIVE belt Inspect the belt for signs of excessive wear frayed edges missing cogs and cracks Replace the QUICKDRIVE belt every 2000 miles 3200 km and whenever inspection reveals excessive wear or damage Special tools are required to remove and install the QUICKDRIV...

Page 104: ... and apply downward pressure while measuring at point 2 This measurement should be 1 1 4 inches 3 2 cm Drive Belt Adjustment 1 Loosen the 7 16 inch jam nut on the belt width adjuster 2 Using a 1 8 inch Allen wrench turn the set screw inward clockwise to increase the distance between the sheaves or outward counter clockwise to decrease the distance 3 Tighten the jam nut 1 2 ...

Page 105: ...ward motion 2 Turn the ignition key off Wait for the engine to come to a complete stop 3 Lock the parking brake 4 Remove the left side panel 5 Rotate the driven clutch counter clockwise 1 4 turn by hand to ensure forward engagement 6 Locate the L wrench in the tool kit Install the wrench into the open threaded hole in the outer sheave of the clutch 7 Turn the wrench clockwise until the sheaves ope...

Page 106: ...n the open position install the drive belt TIP Install the belt so that the numbers can be read correctly on the left side of the vehicle or in the direction in which the belt was originally installed 2 Wiggle the belt to remove slack while removing the L wrench 3 Reinstall the side panel 4 Break in the new belt See page 67 ...

Page 107: ...l needs snow for lubrication Excessive wear indicates insufficient lubrication A new rail slide can cause faster heat build up in limited lubrication resulting in excessive wear WARNING Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure loss of vehicle control and loss of braking ability which can result in serious injury or death Avoid ope...

Page 108: ...nd alignment TIP Tension adjustments should be made only after the track is warmed up and limber 1 Turn the engine off 2 Lift the rear of the snowmobile and safely support it off the ground 3 Place the recommended weight or downward pressure on the track at the specified distance see chart ahead of the center of the rear idler wheel 4 Measure at the point where the weight is hanging TRACK TENSION ...

Page 109: ...e equal adjustment on both sides of the track 9 Repeat the measurement on the other side of the track TIP Check more frequently when the snowmobile is new 10 Start the engine and slowly rotate the track at least five revolutions Let the track come to a stop do not apply brakes 11 Check track alignment see page 108 and adjust as necessary 12 Tighten the locknuts 13 Tighten the idler shaft bolts 14 ...

Page 110: ... Stop the engine and let the track come to a stop do not apply brakes 3 Inspect track alignment by looking through the track window to make sure the rails are evenly spaced on each side If the track runs to the left loosen the idler shaft bolts then loosen the left locknut and tighten the left adjusting bolt If the track runs to the right loosen the idler shaft bolts then loosen the right locknut ...

Page 111: ...109 MAINTENANCE Steering System Steering Inspection Each week or before a long ride check all steering system fasteners and tighten if necessary ...

Page 112: ...hicle weight compressing the suspension measure 10 inches 25 4 cm forward from the center of the ski mounting bolt See illustration At this point measure between the skis This is measurement X 3 Perform the same measurement rearward from the center of the ski mounting bolt This is measurement Y 4 The X measurement should be 1 8 1 4 inch 3 6 mm greater than the Y measurement If the skis are misalig...

Page 113: ...cle control while turning on hard packed snow or ice Check skags before each use of the snowmobile to ensure positive steering characteristics Skags must be replaced when worn to half their original diameter TIP Carbide skags must be replaced if any abnormal wear or chipping is found Skag Replacement 1 Raise and support the front of the snowmobile so the skis are approximately 6 inches 15 2 cm fro...

Page 114: ...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 rails Replace when worn to top of groove Minimum Thickness ...

Page 115: ...onnect the red positive battery cable last 4 Remove the battery Battery Installation When installing a new battery make sure it s fully charged prior to its initial use Using a new battery that has not been fully charged can damage the battery and result in a shorter life It can also hinder vehicle performance Follow the battery charging instructions on page 115 before installing the battery 1 Ens...

Page 116: ...cted during the storage period and will automatically charge the battery if the voltage drops below a pre determined point Battery Charging The following battery charging instructions apply only to the installa tion of a sealed battery Read all instructions before proceeding with the installation of this battery The sealed battery is already filled with electrolyte and has been sealed and fully ch...

Page 117: ...y explode causing severe injury or death Always watch charging times carefully Stop charging if the battery becomes very warm to the touch Allow it to cool before resuming charging Tip Always verify battery condition before and 1 2 hours after the end of charging State of Charge Voltage Action Charge Time Using constant current charger standard amps specified on top of battery 100 12 8 13 0 volts ...

Page 118: ...ventive measures to aid against deterioration and to prolong the useful life of many components See page 122 for the part numbers of POLARIS products Cleaning and Preservation Proper storage starts with cleaning washing and waxing the hood side panels chassis and plastic parts Wipe down remaining surfaces with a damp cloth Clean and touch up with paint any rusted or previously painted surfaces Be ...

Page 119: ...od of more than 60 days the engine must be fogged with fogging oil Follow the engine fogging instructions provided on the container Always add Carbon Clean or a fuel conditioner stabilizer to the fuel tank Follow the instructions on the container running the engine for five minutes to get additives through the entire fuel system Top off with fresh fuel Do not allow the snowmobile to run out of fue...

Page 120: ...nches 118 cm Brake Type Hayes Phantom Phantom Lite Drive Clutch Center Distance 11 5 inches 29 cm Drive Belt P N 3211115 Drive Clutch P 85 Driven Clutch LW Team Roller Reverse Reverse Transmission Electronic Reverse Engine and Cooling Engine S4769 6044 OR6G RMK S4770 6044 OR6G PRO RMK Displacement 599 cc Cylinders 2 Bore x Stroke mm 77 25 x 64 Alternator Output 400 watt Throttle Body Mikuni Oil In...

Page 121: ... 72 Pitch 2700 3350 9000 11000 10 54 1321685 Black Green 7042083 LH BLK PUR TEAM LW 7043363 56 42 36 LW ER 5135403 20 42 72 Pitch Clutching Chart ALTITUDE Meters Feet Drive Clutch Shift Weight Drive Clutch Spring Driven Clutch Spring Driven Helix QUICKDRIVE Gearing Pitch Shaded cells indicate factory settings 0 450 0 1500 10 64 1321585 Black Green 7042083 LH BLK PUR TEAM LW 7043363 56 42 36 LW ER ...

Page 122: ... inches 122 cm RMK ASSAULT 46 5 inches 118 cm All Other Brake Type Hayes Phantom Lite Drive Clutch Center Distance 11 5 inches 29 cm Drive Belt P N 3211115 Drive Clutch P 85 Driven Clutch LW Team Roller Reverse Reverse Transmission Electronic Reverse Engine and Cooling Engine S4775 8044 OR8G RMK 155 S4773 8044 OR8G All Other Displacement 794 cc Cylinders Monoblock Bore x Stroke mm 85 x 70 Alternat...

Page 123: ...20 42 72 Pitch 3000 3600 10000 12000 10 58 1321588 140 330 7043829 LH BLK PUR TEAM LW 7043363 56 42 36 LW ER 5135403 20 42 72 Pitch Clutching Chart ALTITUDE Meters Feet Drive Clutch Shift Weight Drive Clutch Spring Driven Clutch Spring Driven Helix QUICKDRIVE Gearing Pitch Shaded cells indicate factory settings 0 600 0 2000 10 68 1322427 140 330 7043829 LH BLACK Team 7043063 56 42 36 LW ER 5135403...

Page 124: ... qt 95 l 2873106 SCL Synthetic Chaincase Lubricant gal 3 8 l Grease Specialized Lubricants 2871312 Grease Gun Kit All Season 3 oz 89 ml 2871322 All Season Grease 3 oz 89 ml cartridge 2871423 All Season Grease 14 oz 414 ml cartridge 2871329 Dielectric Grease Nyogel Coolant 2871534 Polaris Antifreeze 60 40 Premix qt 95 l 2871323 Polaris Antifreeze 60 40 Premix gal 3 8 l Additives Miscellaneous 28713...

Page 125: ...ake sure the fuel valve is on Make sure tank contains fuel Ice may be in the fuel line filter or pump Add isopropyl alcohol to the fuel system SEE YOUR DEALER Poor engine compression This indicates a major engine problem that must be repaired before operating SEE YOUR DEALER Engine lacks power Fouled or defective spark plug s Replace the plug s Fuel filter loss of high RPM power SEE YOUR DEALER Pl...

Page 126: ...away from slow speed Sheared teeth on QUICKDRIVE belt Replace QUICKDRIVE belt Drive belt surface flat spots Inspect and replace as needed Noise in drive system Broken drive clutch components SEE YOUR DEALER Bearing failure chaincase jackshaft or front drive shaft SEE YOUR DEALER Drive belt surface flat spots Inspect and replace as needed Drive chain loose or worn sprocket teeth broken Inspect and ...

Page 127: ...void riding in high ambient temperatures Check for snow ingestion Ice and snow build up between track and tunnel Warm the engine at least five minutes Take the drive belt off the snowmobile in extremely cold weather and warm it up Break snowmobile loose from the snow Poor engine performance Check for fouled plugs and water ice or dirt in the fuel tank or fuel line Loading snowmobiles onto trailers...

Page 128: ... on page 50 Too little weight transfer when climbing Refer to the suspension adjustment and set up information beginning on page 50 Machine darts from side to side Check ski alignment see page 110 Make sure spindles and all steering components turn freely Check for excessive play in steering assembly see your dealer Ensure skags are straight on skis Front end pushes Check for worn skags Check for ...

Page 129: ...contained in this manual Your dealer is also familiar with POLARIS policies and procedures and will be happy to assist you When contacting us about parts service or warranty always provide the following information Use the page provided near the front of your Owner s Manual to record the identification numbers of your snowmobile and its engine POLARIS Customer Service United States 1 888 704 5290 ...

Page 130: ...es not cover accidental damage normal wear and tear abuse or improper handling The warranty also does not cover any snowmobile that has been structurally altered neglected improperly maintained used for racing or used for purposes other than for which it was manufactured The warranty does not cover any damages that occur during trailer transit or as a result of unauthorized service or parts In add...

Page 131: ...o Obtain Warranty Service If your snowmobile requires warranty service you must take it to a POLARIS dealer authorized to repair POLARIS snowmobiles When requesting warranty service you must present your copy of the Warranty Registration form to the dealer The cost of transportation to and from the dealer is YOUR responsibility POLARIS recommends that you use your original selling dealer however y...

Page 132: ...overage in the event of a warranty claim This warranty also excludes failures resulting from improper lubrication improper engine timing improper fuel surface imperfections caused by external stress heat cold or contamination operator error or abuse improper component alignment tension adjustment or altitude compensation failure due to snow water dirt or other foreign substance ingestion contamina...

Page 133: ... any authorized POLARIS dealer who sells the same line as your vehicle Outside the Country where your vehicle was purchased If you are traveling temporarily outside the country where your vehicle was purchased you should take your vehicle to an authorized POLARIS dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence ...

Page 134: ...you receive safety information and notices regarding your vehicle Notice If your vehicle is registered outside of the country where it was purchased and you have not followed the procedure set out above your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind other than safety bulletins Vehicles registered to Government officials or military personnel on assign...

Page 135: ...components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this warranty is the responsibility of the vehicle owner This emissions limited warranty does not cover components whose failure does not increase the vehicle s regulated emissions For exhaust emissions emission related components include any engine parts related to the following...

Page 136: ...by a defect in material or workmanship This limited warranty does not cover damage due to accidents abuse or improper handling maintenance or use This limited warranty also does not cover any engine that has been structurally altered or when the vehicle has been used in racing competition This limited warranty also does not cover physical damage corrosion or defects caused by fire explosions or ot...

Page 137: ...er each time your snowmobile is serviced This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 3200 km ...

Page 138: ...136 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 139: ...ng System Bleeding 93 Cooling System Flushing 92 Customer Service 127 D DET 32 33 Detonation Elimination Technology 32 33 Diagnostic Display Codes 48 49 Diagnostic Display Mode 47 Disabled Operators 12 Display Standard Metric 40 Drive Belt Adjustment 102 Belt Safety 18 Break In 67 Break In QUICKDRIVE 67 Condition 101 Condition QUICKDRIVE 101 Installation 104 QUICKDRIVE Belt Handling 29 Removal 103...

Page 140: ...Inspection Pre Ride 56 Instrument Cluster 34 49 Intake Filters 87 Intake Silencer 18 L Lights 99 Headlight Replacement 99 Taillight Brake Light 99 Lubrication 84 86 Rear Suspension 84 M Maintenance Interval Table 80 82 Maintenance Program 79 Maintenance Recommendations 9 Maneuverability 18 Metric Standard Display 40 N Noise 6 O Odometer Engine Hour Display Area 39 Oil Change Chaincase 85 Oil Filte...

Page 141: ...9 112 Steering System Inspection 61 Stopping Emergency 76 Storage Procedures 116 117 Storage Cargo 28 Storage Daily 77 Storage Tools 28 S Survival Preparation 12 Suspension Adjustments 50 54 Suspension Inspection Pre Ride 57 Suspension Lubrication Rear 84 Suspension Set Up Fine Tuning 52 Switches Engine Stop Switch 72 Mode Select Buttons 34 Mode Set Switch 34 Throttle Safety Switch 72 T Taillight ...

Page 142: ...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 ...