Polaris 2004 RMK Page 88 Owner'S Manual Download

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MAINTENANCE

General Maintenance

Brake Components

Air cooled model

Liquid cooled model

1. Brake Caliper

2. Chaincase

3. Brake Disc

4. Backing Plate

5. Brake Pad Material (Replace when thickness is less than 1/16

″

Excessive Lever Travel

Hydraulic brakes are self-adjusting, but if excessive brake pad

clearance develops, as described on page 85, the machine should be

returned to an authorized Polaris dealer for inspection and adjustment.

Summary of Contents for 2004 RMK

Page 1: ...2004 RMK Switchback Snowmobiles 2004 RMK Switchback Snowmobiles Owner s Manual for Vehicle Maintenance and Safety Owner s Manual for Vehicle Maintenance and Safety...

Page 2: ...haust from this product contains chemicals known to cause cancer birth defects or other reproductive harm PROPOSITION 65 WARNING Snowmobile engines discharge fuel and exhaust which contain chemicals k...

Page 3: ...A Polaris owner s Web site designed just for YOU S Technical tips S New product introductions S Event schedules S Parts and Service Manual information S Exciting details about The Way Out Check it ou...

Page 4: ...uction components some minor discrepancies may result between the actual vehicle and the information presented in this publication Depictions and or procedures in this publication are intended for ref...

Page 5: ...safe and enjoyable operation of your vehicle be sure to follow the instructions and recommendations in this owner s manual Your manual contains instructions for minor maintenance but information abou...

Page 6: ...and features The Perfect Fit 29 This section explains how to tailor the suspension and other features for an optimum riding experience Pre Ride Inspections 43 This section explains procedures that mu...

Page 7: ...ur model may differ n Follow the maintenance program outlined in this manual Preventive maintenance ensures that critical components of the snowmobile are inspected by your dealer at specific mileage...

Page 8: ...body for snowmobile development recommends that snowmobiles conform to prescribed sound levels Polaris snowmobiles are engineered to conform to these SAE standards Our muffler systems are designed to...

Page 9: ...numbers are essential to its recovery and identification Remove the spare key and store it in a safe place Your key can be duplicated only by mating a Polaris key blank with one of your existing keys...

Page 10: ...n your vehicle or in this manual alerts you to the potential for personal injury The safety alert warning indicates a potential hazard that may result in serious injury or death The safety alert cauti...

Page 11: ...We strongly recommend that the operator check major and vital safety components before every ride All Polaris snowmobiles are designed and tested to provide safe operation when used as directed Failur...

Page 12: ...engine running Turn off the ignition raise the hood make the adjustment secure shields and guards secure the hood and then restart the engine to check its operation Never hold the snowmobile up or sta...

Page 13: ...s Always tell someone where you re going and how long you expect to be gone If it isn t possible to ride with others and you must travel into remote areas always carry survival equipment that s approp...

Page 14: ...table is provided on page 21 for your reference To better enjoy your ride be prepared be warm and be comfortable Disabled Operators Safe operation of this rider active vehicle requires good judgement...

Page 15: ...feet per second If you look back for only two seconds your machine will travel about 120 feet If your speed is 60 MPH your machine will travel about 180 feet in two seconds Traveling at night requires...

Page 16: ...ur view Always leave yourself a way out Variances in snow depth and or water currents may result in uneven ice thickness Always check with local residents or authorities for general information on con...

Page 17: ...now or ice may lead to loss of vehicle control and result in serious injury or death Slow down to maintain control under these conditions It s dangerous to drive on ice or other slippery surfaces If i...

Page 18: ...er side of the hill If you re unable to continue up a hill turn the machine downhill before it loses momentum If this isn t possible spin the track just enough to dig in to prevent it from rolling bac...

Page 19: ...remote don t defeat the purpose of the guard by removing it It s provided for your safety Drive Belt Do not operate the engine with the drive belt removed Any servicing that requires operation without...

Page 20: ...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...

Page 21: ...track and or engine If the machine becomes stuck in snow clear the running board area of snow then step down the snow in front of the machine so that when the throttle is opened the snowmobile will b...

Page 22: ...to begin building your operating experience S Before allowing someone else use your snowmobile know the ex tent of their operating skills Check to see if they ve taken a snow mobile safety course and...

Page 23: ...26 10 6 21 37 53 69 85 100 116 132 148 Wind Speeds Great er Than 40 MPH Have Little Added Little Danger For Properly Clothed Person Increasing Danger Great Danger Have Little Added Effect Clothed Per...

Page 24: ...nder the hood on the clutch cover Do not operate engine with hood open Do not attempt adjustment with engine running Do not operate engine with this guard open Never run engine with drive belt removed...

Page 25: ...g in serious injury or death To avoid loss of control always S Look behind before and while backing S Avoid sharp turns S Shift to or from reverse only when stopped S Apply throttle slowly NOTE For mo...

Page 26: ...an approved helmet eye protection and adequate cloth ing while operating this vehicle S This vehicle is designed for adult use only Check local laws for age re quirements S When operating with a passe...

Page 27: ...include a fuel gauge 2 Ignition Switch 3 Brake Lever 4 Speedometer may include indicator warning lights 5 Tachometer may include indicator warning lights 6 Engine Stop Switch see page 59 7 Throttle Co...

Page 28: ...strated on this page Not all models come with these features Refer to your Owner s Manual Supplement for a list of features on your machine Accessories are available from your Polaris dealer 1 Headlig...

Page 29: ...TROLS Features 1 Hood 2 Headlight 3 Windshield 4 Handlebar 5 Seat 6 Storage Compartment 7 Taillights 8 Snow Flap 9 Track 10 Suspension 11 Trailing Arm 12 Nosepan 13 Front Bumper 14 Skis 8 4 3 2 1 13 5...

Page 30: ...f these conditions exists and the sensor remains activated see your Polaris dealer Possible Cause Solution Poor quality fuel Replace with higher quality fuel Improper jetting Verify and adjust per jet...

Page 31: ...one area at a time in order to properly evaluate the change All snowmobile suspensions have a front and a rear suspension each of which has adjustment options Independent Front Suspension IFS The IFS...

Page 32: ...bumper down as far as it will go on the shock rod and test ride the machine The bumper will move up on the rod in direct relation to the amount of travel If the shock travel is full the bumper will b...

Page 33: ...used to achieve the desired ride The shocks have a wide range of adjustment capability By turning the screw clockwise the compression of the shock increases stiffening the ride When adjusting these s...

Page 34: ...Increasing the spring preload too much may adversely affect the handling of the snowmobile and the performance of the suspension Never exceed one inch of preload beyond the factory settings and ensure...

Page 35: ...if spring preload alone isn t sufficient and further adjustment is desired to control suspension stiffness See your Polaris dealer for more information Changing shock valving on RydeFX and RydeFX SOL...

Page 36: ...so you can evaluate the change For further assistance see your dealer Suspension Performance Tips S Rider weight usually determines the position at which the spring pre load should be set However thi...

Page 37: ...n the ground and the rear bumper at the exact location used for measurement X This is measurement Y To determine sag commonly referred to as ride in subtract measurement Y from X Sag X Y Adjust sag by...

Page 38: ...up Your set up may vary based on your desired riding style 1 Turn screw clockwise to stiffen compression 2a Limiter strap in high position increases ski pressure 2b Limiter strap in low position decr...

Page 39: ...ew clockwise to increase compression valving and stiffen the ride or counterclockwise to reduce compression and soften the ride There are approximately three full turns of adjustment available If bott...

Page 40: ...other part of the machine when the handlebar is turned fully to the left or right 4 Torque the handlebar adjuster block bolts to 11 13 ft lbs 15 17 6 Nm 5 Replace the handlebar cover Handlebar with R...

Page 41: ...odels See your Polaris dealer Use only Polaris parts and accessories on your Polaris snowmobile Use of unapproved parts and accessories may result in S Non compliance with government industry requirem...

Page 42: ...may be reduced on hard packed snow or ice Installing studs on models without wear strips will result in damage to the cooler or tunnel Always ensure that wear strips are installed before installing st...

Page 43: ...mmended studding and skags Inspect skags and studs frequently Worn studs or skags may reduce steering and braking control on hard packed snow and ice Replace worn studs and skags to maintain proper ba...

Page 44: ...ng chart for recommended traction accessories Components as viewed from the rear of the track 1 Top of tunnel 2 Wear strip 3 Track 4 Wear strip mounting holes Never add shims to the wear strip Track d...

Page 45: ...s evenly and smoothly The lever should immediately return to the idle position without binding or hesitation If the throttle does not function smoothly DO NOT start the engine Have the throttle servic...

Page 46: ...ezing the brake lever Proper operation depends on an adequate supply of air and moisture free hydraulic brake fluid in the system If the brake lever feels spongy when squeezed check the level and cond...

Page 47: ...lock or it may break To release the lock squeeze the brake handle until the lever returns to the unlock position The park brake light on the console will light up when the park brake lever lock is se...

Page 48: ...rack edges and cause other track damage Examples of inadequate lubrication would include frozen bodies of water without snow cover icy trails and no snow conditions NOTE Track damage or failure caused...

Page 49: ...a clear area all around your snowmobile including an area clear of bystanders There s always the possibility of some sideways vehicle movement of applying a little more throttle than intended or of d...

Page 50: ...gine slows or wants to stop use intermittent choking to the HALF ON position Before starting the engine always refer to all safety warnings pertaining to snowmobile operation Never start your snowmobi...

Page 51: ...le to OFF If the engine slows or wants to stop use intermittent choking to HALF ON Starting a Warm Engine 1 Turn key to ON 2 Pull kill switch shut off switch up to RUN 3 Grasp starter handle and pull...

Page 52: ...three hours of operation will damage close fitted engine parts Do not operate at full throttle or high speeds for extended periods during the first three hours of use Vary the throttle openings and ma...

Page 53: ...he highest performance products available for your snowmobile s engine Refer to the table below to determine the recommended oils for use in your Polaris snowmobile Never mix brands of oil Serious che...

Page 54: ...m from side to side This will loosen frozen snow from the ski bottoms allowing the machine to move forward more easily 6 The engine drive system and track are now properly warmed up and the machine ma...

Page 55: ...the tank Do not fill the tank neck S If gasoline spills on your skin or clothing immediately wash it off with soap and water and change clothing S Never start the engine or let it run in an enclosed a...

Page 56: ...you change fuels It s very important to the life of your engine that you use this feature When using fuels with a pump posted octane rating of 91 or higher turn the key switch to ON PREM When the eng...

Page 57: ...f fuel left in the tank when the mechanical fuel gauge reads RES Fuel System Deicers If you use non oxygenated fuel Polaris recommends the regular use of isopropyl based fuel system deicer Add one to...

Page 58: ...y 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 Always maintain the oil level above...

Page 59: ...fuel may result in piston burning bearing failure or complete engine failure A rich mixture too much fuel too little air may foul plugs and cause generally poor engine performance A lean mixture may...

Page 60: ...f the snowmobile is operated outside this production temperature and or altitude range The main jet installed in production is not correct for all altitudes and or temperatures NOTE It s the owner s r...

Page 61: ...on shown in the illustration B Apply a slight amount of throttle A properly functioning switch must shut down the engine The throttle safety switch is designed to stop the engine whenever all pressure...

Page 62: ...the throttle cable may cause the safety switch to activate preventing the engine from starting If this occurs return the machine to an authorized Polaris dealer for service If an emergency exists and...

Page 63: ...ngine Half throttle or less Engine Stop Switch Interrupts ignition circuit All Throttle Safety Switch Interrupts ignition circuit All Tether Switch Option Interrupts ignition circuit All Excessive or...

Page 64: ...guard 2 Push on the inner sheave of the clutch and rotate clockwise slightly to relieve belt tension 3 Starting at one of the tower struts wind the strap counterclockwise around the clutch as shown 4...

Page 65: ...n it s restarted Disengaging Reverse Push the yellow reverse button on the left hand control for one second and release The engine will slow and and begin to rotate forward The light on the instrument...

Page 66: ...fore towing and have a rider on the towed snowmobile to operate the brake and steering when necessary Objects towed with a rope have no braking power and can easily collide with the rear of the snowmo...

Page 67: ...ontinue maintenance checks at 1000 mile 1600 km intervals All necessary replacement parts and labor incurred with the exception of authorized warranty repairs become the responsibility of the register...

Page 68: ...tle lever operation Daily 43 59 Check operation of headlights taillight brakelight Daily 47 Check park brake function Daily 45 Secure hood Daily 46 Check track alignment X 98 Steering arm and tie rod...

Page 69: ...vot X X X 70 Flush Chaincase X X 73 Grease driveshaft bearing always perform before storage X X 72 Check and drain water trap X X 78 Grease rear suspension pivot shafts X X 71 Grease jackshaft bearing...

Page 70: ...ntenance and services performed on the snowmobile 150 Mile 240 km Initial Maintenance Inspection Authorized Polaris Servicing Dealer Servicing Technician Date Mileage 500 Mile 800 km Maintenance Inspe...

Page 71: ...Additional Services Performed Authorized Polaris Servicing Dealer Servicing Technician Date Mileage Type of Service Additional Services Performed Authorized Polaris Servicing Dealer Servicing Technici...

Page 72: ...left and right spindles Raise the front end of the ma chine to permit better grease entry into the spindle area S Lubricate both of the front ski pivots at the fittings as shown S Grease the jackshaf...

Page 73: ...m after that and before off season storage each year Lack of lubrication will adversely affect your ride and the life of the suspension For detailed information about suspension lubrication and adjust...

Page 74: ...24 4 Nm Driveshaft Bearing Greasing Inject grease into the fitting on the speedometer drive adaptor until grease purges from inside or outside the bearing seal approximately two pumps Throttle Cable...

Page 75: ...level surface The oil level should be between the safe marks on the dipstick A Add Polaris synthetic chaincase oil through the dipstick opening Do not overfill See page 110 for the part numbers of Pol...

Page 76: ...failure Refer to your Owner s Manual Supplement for the specific spark plug to be used in your machine A new engine can cause temporary spark plug fouling due to the preservative added during the asse...

Page 77: ...range for the engine and the service NOTE The tip should not be white A white insulator tip indicates overheating caused by use of an improper spark plug or incorrect carburetion adjustments 2 Wet Fo...

Page 78: ...lly to remove any accumulation of snow NOTE These illustrations are general representations Your model may differ in appearance 1 Intake Foam Filter 2 Air Intake box 1 1 2 Operating the snowmobile wit...

Page 79: ...follow the oil recommendation chart on page 51 The use of other lubricants may cause improper function of the valve mech anism and increase the frequency of required cleaning due to excessive build up...

Page 80: ...off 2 Position a container or shop towels to catch the contaminated gasoline 3 Slide the clamp 1 away from the drain plug 2 and remove the drain plug from the sediment tube 4 Wipe residue from the pl...

Page 81: ...cially designed for use on Polaris products We strongly recommend the use of only Polaris replacement parts Edge models use an oil filter that s built into the oil sending unit located in the bottom o...

Page 82: ...re synchronized or balanced is important Properly adjusted carburetors can greatly improve engine performance fuel economy engine life and reliability If you notice any of the following conditions the...

Page 83: ...Mixture The coolant supplied in the system is a 50 50 mixture of ethylene glycol and distilled water This mixture provides protection against freezing at temperatures to 34 F 37 C If greater protectio...

Page 84: ...dealer Coolant Level The coolant level in the coolant bottle must be maintained at the full cold line on the coolant bottle when the engine is cold Flushing the Cooling System To ensure that the coola...

Page 85: ...d 4 Add coolant to the coolant bottle to the maximum mark 5 Start the engine and run at a fast idle for two to three minutes Loosen the bleed screwoccasionally to purge any trapped air 6 Stop the engi...

Page 86: ...to the tensioner side Lock the brake lever lock or have an assistant hold the brake lever firmly 2 Loosen the adjuster bolt jam nut A 3 Finger tighten the adjuster bolt B until it can no longer be ad...

Page 87: ...e replaced when the brake pad material becomes thinner than the backing plate approximately 1 16 A kit is available for replacing brake pads See your dealer A Brake failure during operation can result...

Page 88: ...rake Disc 4 Backing Plate 5 Brake Pad Material Replace when thickness is less than 1 16 Excessive Lever Travel Hydraulic brakes are self adjusting but if excessive brake pad clearance develops as desc...

Page 89: ...s 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 fl...

Page 90: ...he bleedervalve and direct theflow of fluid into an approved container 4 Squeeze the brake lever a full stroke Then unscrew the bleeder valve 3 4 of a turn to release air 5 Close the bleeder valve and...

Page 91: ...he center of the headlight and make a mark on the wall 3 Start the engine and turn the headlight switch to high beam 4 Observe the headlight aim The most intense part of the headlight beam should be a...

Page 92: ...t spring carefully around wire harness 2 and flip to outside of housing 3 With the wire harness attached to the bulb 3 withdraw bulb from housing 4 Grasp bulb by metal base and carefully separate bulb...

Page 93: ...only O E M belts be used Other belts may match the dimensions but can drastically change the shift pattern resulting in poor performance See your dealer for service and adjustments NOTE A worn belt wi...

Page 94: ...Drive Belt Removal 1 Be sure the key switch is off and the engine has come to a complete stop Apply the brake or lock the parking brake if equipped 2 Open the hood remove the clutch guard retaining p...

Page 95: ...n the belt removal procedures 2 Turn the driven clutch moveable sheave clockwise while pushing inward and forcing the belt down between the sheaves 3 Hold the belt down between the sheaves and roll th...

Page 96: ...ounterclockwise to reduce the distance between the sheaves Do not rotate past the 1 position 3 Torque the bolts to 4 6 ft lbs 5 4 8 1 Nm TEAM Clutch 1 Loosen the 7 16 jam nut on the belt width adjuste...

Page 97: ...aintenance Always keep the tool kit with the snowmobile Your tool kit will contain only the tools applicable to your model 1 Emergency Start Strap manual start models 2 Phillips Screwdriver 3 Tubular...

Page 98: ...ter Survival Kit STrail Map SOwner s Manual SFirst Aid Kit Fall Tune Up For maximum performance arrange for a fall service tune up with your Polaris dealer His experienced and trained service technici...

Page 99: ...where the weight is hanging Weight Measurement Location Measurement 10 lbs 4 54 kg 16 ahead of rear idler shaft 3 8 1 2 1 1 3 cm 4 Check for specified slack between the wear surface of the track clip...

Page 100: ...cause excessive wear to the track and slide rail 1 Safely support the rear of the machine with the track off the ground 2 Start the engine and apply a small amount of throttle until the track turns s...

Page 101: ...ive wear NOTE If excessive Hi fax wear occurs due to poor snow conditions additional wheel kits are available See your dealer for more information NOTE Track damage or failure caused by operation on i...

Page 102: ...tem Steering Inspection and Adjustment Each week or before a long ride check fasteners and tighten if necessary Specific fasteners that should be checked are marked with a in the following illustratio...

Page 103: ...between the skis at point X should be 1 8 to 1 4 greater than at point Y NOTE If the skis are misaligned we recommend that your dealer correct the alignment since camber adjustment may also be affect...

Page 104: ...from the ground 2 Remove the attaching nuts and pry the skag downward 3 Remove the forward portion of the skag Reverse this procedure for new skag installation Worn skis and or skags will adversely a...

Page 105: ...edless repairs and down time Before beginning any snowmobile trip a visual inspection will uncover potential problems Check the following items on a weekly basis or before any long trip n Check rear i...

Page 106: ...t and corrosion on precision engine parts during storage Whenever the machine is stored for a period of more than 60 days the engine must be fogged with fogging oil Follow the engine fogging instructi...

Page 107: ...e your dealer Engine and Carburetor Protection Using a fuel stabilizer and topping off the fuel tank eliminates the need to drain the fuel system If you prefer to drain the fuel tank use the following...

Page 108: ...epare and maintain the battery as outlined on page 107 Track and Suspension Moderate track tension should be maintained during summer storage The machine should be supported off the ground to allow th...

Page 109: ...m contact with the skin eyes or clothing If contact occurs seek immediate medical attention KEEP OUT OF REACH OF CHILDREN EXTERNAL Flush with water INTERNAL Drink large quantities of water or milk Cal...

Page 110: ...positive battery cable second 5 Carefully lift the battery out of the snowmobile Do not tip it sideways or spill electrolyte Tap water contains minerals that will damage a battery and shorten its life...

Page 111: ...rge it to the proper level S Store it in a cool dry place S Check and or charge monthly Before using the battery take it to your dealer for testing and recharging NOTE Batteries may freeze if not full...

Page 112: ...case Lubricant qt 2872951 Synthetic Chaincase Lubricant 12 oz Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 2871322 Premium All Season Grease 3 oz cartridge 2871423 Prem...

Page 113: ...35 Adjust torsion spring blocks page 36 or install optional torsion springs to achieve correct sag dimensions Move limiter strap on front torque arm to low position see set up decal or page 36 Front...

Page 114: ...RPM Avoid riding in high ambient temperatures Ice and snow build up between track and tunnel Warm the engine at least five minutes Take the drive belt off the machine in extremely cold weather and wa...

Page 115: ...clearance and replace if necessary SEE YOUR DEALER Harsh drive clutch engagement Drive belt worn or too narrow Excessive belt sheave clearance Replace drive belt SEE YOUR DEALER Drive belt turns over...

Page 116: ...Worn drive belt Excessive belt sheave clearance Loose torque stop Sticky clutch Inspect and replace if necessary SEE YOUR DEALER Inspect and adjust SEE YOUR DEALER Engine doesn t start electric start...

Page 117: ...satisfactori ly when dried Running too lean a mixture too small a main jet will cause seizure resulting in loss of power SEE YOUR DEALER This indi cates a major engine problem that must be repaired be...

Page 118: ...3 Dealer name 7 Previous correspondence 4 Date of purchase Use the page provided near the front of your Owner s Manual to record the identification numbers of your snowmobile and its engine Polaris C...

Page 119: ...not caused by a defect in material or workmanship The warranty does not cover accidental damage normal wear and tear abuse or improper handling The warranty also does not cover any snowmobile that ha...

Page 120: ...st 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 deal...

Page 121: ...cuit breakers Fuses Light bulbs Sealed beam lamps Electronic components Idler wheels Warranty applies to the product only and does not allow for coverage of personal loss Some items are considered con...

Page 122: ...tomatic with no additional paperwork required The free Second Year Engine Service Contract is subject to a 50 deductible per visit Regular documented service maintenance visits are required to validat...

Page 123: ...ake your vehicle to an authorized Polaris dealer You must show the dealer photo identification from the country of the selling dealer s authorized location as proof of residence Upon residence verific...

Page 124: ...Away 18 Controls 25 26 Controls and Linkage 105 Coolant Level 82 Coolant Mixture 81 Cooling 81 83 D D E T Flash Signals 28 D E T Troubleshooting 28 Daily Storage 64 Detonation Elimination Technology...

Page 125: ...TION 48 64 Operation 24 Operator Safety 8 21 P Passenger 22 PERC 63 Plug Cleaning 78 POLARIS PRODUCTS 110 Powder Snow Operation 19 PRE RIDE INSPECTIONS 43 47 Premium Fuel Switch 54 Premium Fuel Switch...

Page 126: ...Stop 95 Torsion Spring Tension 36 Towing 64 Track 106 Track Alignment 98 Track Inspection 46 99 T Track Lubrication 99 Track Maintenance 97 99 Track Tension 97 Track Warm Up 52 Track Warning 23 Tracti...

Page 127: ...your nearest Polaris dealer call 1 800 POLARIS or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 763 417 8650 Fax 763 542 0599 Part No 9918225 Rev 03 Printed in U...

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