Polaris 600 PRO-RMK Page 107 Owner'S Manual Download | Manualshive

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105

MAINTENANCE

Rear Suspension Lubrication

Lubricate the suspension pivot shafts with POLARIS All Season Grease
at the intervals outlined in the Periodic Maintenance Table beginning on
page 99 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.

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Summary of Contents for 600 PRO-RMK

Page 1: ...Snowmobile Owner s Manual for Maintenance and Safety 600 PRO RMK 800 PRO RMK 800 RMK ASSAULT 800 SKS...

Page 2: ...tions and safety precautions 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 cont...

Page 3: ...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 pr...

Page 4: ...rmation 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...

Page 5: ...and features The Perfect Fit 64 This section includes suspension set up information and explains how to make additional suspension adjustments for the perfect riding experience Pre Ride Inspections 76...

Page 6: ...4...

Page 7: ...re 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...

Page 8: ...at 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 o...

Page 9: ...wrap do not cover the tunnel certification tunnel VIN or emissions certification labels with the wrap If the tunnel wrap doesn t provide an opening for these labels remove the section of wrap where th...

Page 10: ...us 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...

Page 11: ...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 d...

Page 12: ...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...

Page 13: ...r 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 shatterpro...

Page 14: ...eed driving especially at night could result in serious injury or death Always reduce speed when driving at night or in inclement weather Always observe all state and local laws governing snowmobile o...

Page 15: ...rough 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 toget...

Page 16: ...ided in this manual should be considered basic information and is not intended to replace your participation in an avalanche safety training course After reviewing the avalanche information in this ma...

Page 17: ...lowing survival items when riding in mountainous terrain A digital avalanche beacon with new fresh alkaline batteries An avalanche probe A compact shovel and hand saw A backpack preferably an avalanch...

Page 18: ...ey cannot be added later Avoid cotton materials which will freeze if they get wet Wear highly visible gear Try on all gear and equipment to make sure it fits and doesn t interfere with your riding cap...

Page 19: ...to locate current avalanche reports and conditions for your area of operation Get the Picture Slopes steeper than 30 are more prone to avalanches but any slope should be considered avalanche terrain e...

Page 20: ...information pertains to a deep snow mountain snowmobile This type of snowmobile is longer and narrower and has a higher center of gravity when compared to a typical trail snowmobile These features mak...

Page 21: ...omfortable with these maneuvers practice more advanced maneuvers in deep flat snow Learn techniques from more experienced riders Practice placing your feet in different locations on the floorboards to...

Page 22: ...al gear in your backpack and wear the backpack Do not store your survival gear on the snowmobile Always research current avalanche conditions in your area of operation before riding Check with local l...

Page 23: ...ns Careful snowpack evaluation cautious route finding and conservative decision making essential Natural avalanches possible human triggered avalanches likely Small avalanches in many areas or large a...

Page 24: ...rating 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...

Page 25: ...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 an...

Page 26: ...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 D...

Page 27: ...ll 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...

Page 28: ...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 W...

Page 29: ...part number is printed on the label Clutch Warning Belt Removal This warning label is found on the oil bottle USE ONLY SYNTHETIC 2 CYCLE SNOWMOBILE OIL FOR OPTIMUM PERFORMANCE USE VES WARNING Do not o...

Page 30: ...d on the lower console 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...

Page 31: ...ing coolant Press down and turn to release cap 13 PSI Tunnel Warning WARNING Hot Surface Do Not Touch Burn may result Entire top of tunnel may be hot Install only accessories specifically approved for...

Page 32: ...ing in 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 sa...

Page 33: ...ability are greatly reduced Reduce speed and allow extra space to turn or stop Repeated stops from high speed may cause fading or sudden loss of braking ability Parking brake may relax when used for...

Page 34: ...sepan 2 Skis 3 Front Bumper 4 Hood 5 Side Panel Strap 6 Headlight 7 Windshield accessory 8 Handlebar 9 Fuel Filler Cap 10 Operator Seat 11 Taillight 12 Rear Bumper 13 Snow Flap 14 Suspension 15 Track...

Page 35: ...tronic Reverse Button 4 Instrument Cluster 5 Ignition Switch 6 Engine Stop Switch 7 Throttle Control 8 Recoil Starter Handle 9 Handlebar Grip Thumb Warmer Switch 10 Mode Set Switch Console 11 Headligh...

Page 36: ...nue to draw a small amount of current from the battery until the key is turned off This feature is useful for accessing the IDD without starting the engine but turn the key off when the IDD is not in...

Page 37: ...the use of an RCA power adapter If your model is not equipped with an RCA power plug on the handlebar cover an accessory 12 volt RCA adapter or RCA power plug can be purchased from your POLARIS dealer...

Page 38: ...lay Hand warmers Thumb warmer The ECU will close the load shed relay when engine speed exceeds 1500 RPM and chassis voltage exceeds 12 8 VDC If engine speed falls below 1500 RPM or if chassis voltage...

Page 39: ...stance from the floor to the center of the headlight and make a mark on the wall at the same height 4 Start the engine Move the headlight switch to high beam 5 Observe the headlight aim on the wall Th...

Page 40: ...it counter clockwise and slide it upward from the bracket Return the L wrench to the bracket and rotate it clockwise when it s not in use The spark plug wrench secures the spare belt spark plug tool...

Page 41: ...ner is positioned slightly higher than the front loop 6 Slide the container into the engine compartment at an angle 7 Position the container bracket onto the bumper tube and rotate it downward 8 Reins...

Page 42: ...l 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...

Page 43: ...ty for the tunnel is 15 lbs 7 kg Include the weight of the cargo bag when determining cargo weight Rail Scratchers Some models are equipped with rail scratchers to help prevent overheating when riding...

Page 44: ...structions standard instrument cluster If your model is equipped with the Interactive Digital Display IDD please see the IDD Owner s Manual provided with your snowmobile Accessories POLARIS offers a w...

Page 45: ...e 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...

Page 46: ...play dET and the ECU will either limit the maximum engine speed or turn off the engine If the ECU limits RPM the limit will remain active until the driver stops and restarts the engine DETONATION PROT...

Page 47: ...the instrument cluster or IDD Cause of DET Activation Solution Poor quality fuel Replace with higher quality fuel Incorrect ethanol non ethanol fuel resistor installed Check that the fuel setting is...

Page 48: ...of the IDD screen changes to RED and the check engine temperature indicator at the top left of the screen illuminates when the engine is overheating Take action to cool the engine See page 47 The ind...

Page 49: ...ol the engine Drive in loose snow View the coolant level Do not open the pressure cap while the engine is hot Stop the engine and allow it to cool down Add coolant if the level is low Do not add coola...

Page 50: ...by the MODE SET switch on the 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...

Page 51: ...the 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 t...

Page 52: ...resettable 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 a...

Page 53: ...tank 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...

Page 54: ...PM 1 To change which item displays first make sure the information display area is set to display either engine speed or vehicle speed 2 Press and hold the MODE button or the MODE switch for three sec...

Page 55: ...ayed 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 spe...

Page 56: ...nits 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 MO...

Page 57: ...is 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 a...

Page 58: ...uttons 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...

Page 59: ...stem 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 OF...

Page 60: ...st digit 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 a...

Page 61: ...it When 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...

Page 62: ...System 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...

Page 63: ...active 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...

Page 64: ...Type Selection Vehicle Security CAUTION Use a microfiber hand towel to clean the LCD screen Certain products will damage the screen and other plastic surfaces Do not use alcohol to clean the display...

Page 65: ...will display text messages and missed phone calls on the display screen The IDD sub menus and most display features are controlled by either the five button keypad on the IDD or by the MODE SET switch...

Page 66: ...ter ride Step 1 Ride your snowmobile Ride the snowmobile in various terrain to fully experience the existing suspension settings before making any adjustments Step 2 Adjust the rear spring to tune veh...

Page 67: ...ock clickers you can adjust the clickers to control bottoming and adjust ride comfort Turn a clicker counter clockwise to decrease damping for a softer ride Turn a clicker clockwise to increase dampin...

Page 68: ...66 THE PERFECT FIT Suspension Quick Set Up Guide Shock Locations Shock Clicker Adjustments REAR TRACK SHOCK FRONT IFS SHOCKS FRONT TRACK SHOCK SOFTER STIFFER IFS Shock Rear Track Shock SOFTER STIFFER...

Page 69: ...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...

Page 70: ...shock at full extension IFS Shock Spring Settings IFS Remote Reservoir Shock Factory Clicker Settings Factory Spring Factory Installed Length MinimumInstalled Length PRO RMK Monotube 10 5 26 7 cm 9 7...

Page 71: ...nts with the weight of the vehicle removed from the shock and with the shock at full extension NOTICE Never adjust spring preload to an installed length longer than the factory length or shorter than...

Page 72: ...installed lengths as a starting point then test ride before making fine tuning adjustments Do not exceed the minimum and maximum installed length requirements See page 71 Always perform shock spring p...

Page 73: ...ion off the ground Rider Weight Model Factory Installed Length Minimum Installed Length For Factory Installed Springs 160 lbs 73 kg SKS PRO RMK 10 75 27 3 cm 9 8 24 9 cm ASSAULT RMK 10 75 27 3 cm 160...

Page 74: ...ing screws set screws Take care to avoid damaging hand warmer brake switch wires when moving components 1 Brake Lever Master Cylinder 60 80 in lbs 6 7 9 Nm 2 Auxiliary Engine Stop Switch Set Screw 12...

Page 75: ...lock Alignment 1 Slightly loosen the set screw on the bottom of the housing 2 Move the control block to the desired position NOTICE Take care to avoid damaging hand warmer wires when moving components...

Page 76: ...ft lbs 13 5 Nm Torque Steel Bars 18 ft lbs 24 Nm Handlebar Angle Adjustment 1 Securing the handlebar clamp bolts with an Allen wrench loosen each of the four nuts CAUTION Take care to avoid damaging h...

Page 77: ...nowmobile Damage will occur Chaincase Gearing if equipped A speed sensor reads the speed of the brake disc on the jackshaft The engine management system uses this signal to determine vehicle speed If...

Page 78: ...l 113 Chaincase Oil Level if equipped 106 Injection Oil Level 91 Parking Brake Lock Brake Lever Brake System 79 80 118 Auxiliary Shut Off Switch Engine Stop Switch 82 Ignition Switch 82 Headlight Tail...

Page 79: ...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 bolt for tightness 129 Check rear idler adjust...

Page 80: ...your snowmobile resulting in serious injury or death Keep the underhood area free of snow and ice Before driving manually turn the skis to the left and right to be sure ice and snow are not interferi...

Page 81: ...tes low brake fluid level or air in the hydraulic system Refer to the brake bleeding information on page 120 or see your dealer for service Lever Feel If the brake lever feels spongy when squeezed che...

Page 82: ...lace 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 br...

Page 83: ...Side Panel Fasteners The hood and side panels 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 h...

Page 84: ...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 te...

Page 85: ...ull 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 thrott...

Page 86: ...rocedure 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...

Page 87: ...mical 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 f...

Page 88: ...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...

Page 89: ...eak 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...

Page 90: ...ree minutes WARNING A loose track or flying debris could cause serious injury or death Stand clear of the front of the snowmobile and the moving track Never hold the snowmobile up or stand behind it w...

Page 91: ...ors or in a well ventilated area Always turn off the engine before refueling Do not overfill the tank Do not fill the tank neck Do not smoke or allow open flames or sparks in or near the area where re...

Page 92: ...ed 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 P...

Page 93: ...ndicator 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 r...

Page 94: ...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 do...

Page 95: ...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 servic...

Page 96: ...le 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 Electron...

Page 97: ...ansmission 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 s...

Page 98: ...e Damage will occur If the snowmobile becomes inoperable and must be towed and if it isn t possible to use a rigid tow bar attach the tow rope to the ski spindles not to the ski loops to prevent damag...

Page 99: ...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 Specifica...

Page 100: ...rvals 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...

Page 101: ...i 240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 3200 km Pre Season CLUTCH Clutch Alignment Offset without belt 122 I I I Drive Belt Condition 123 I I I I QUICKDRIVE Belt 123 I I I R I Clutches 122 C C...

Page 102: ...aks I I I I Brake Pads 118 I I I I Brake Disc I I I I Parking Brakes 80 I I I I Brake System 79 118 I Brake Fluid 119 I FUEL MANAGEMENT Throttle Lever 93 I I I I I Fuel Lines 112 I I I I Oil Lines 112...

Page 103: ...I I I I I Rear Suspension Fasteners I I I I I Cooling Fins and Shroud I I I I Skags Wear Bars 133 I I I I I Ski Saddle Spindle Bolts I I I I I Drive Chain Tension 117 I I I I I Hood and Side Panel Fas...

Page 104: ...e 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 Too...

Page 105: ...0194 3 Voltage Too Low 4 Throttle Stuck 7 Chassis Relay Driver Circuit Open Grounded 520208 5 Driver Circuit Short to B 3 Exhaust Valve Solenoid 600 Only Driver Circuit Grounded 520215 5 Driver Circui...

Page 106: ...lace 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 ope...

Page 107: ...ed in the Periodic Maintenance Table beginning on page 99 and before seasonal storage When operating in heavy wet snow conditions lubricate every 500 miles 800 km Lack of lubrication will adversely af...

Page 108: ...hole POLARIS recommends the use of POLARIS Synthetic Chaincase Lube See page 148 for the part numbers of POLARIS products Oil Level Check 1 Position the snowmobile on a level surface 2 Remove the fil...

Page 109: ...etal shavings off the plug 3 Insert the tube of a hand pump oil extractor into the fill hole Direct the hose toward the bottom front area of the cover away from the chain sprocket 4 Extract the oil fr...

Page 110: ...See page 134 4 Place a drain pan under the chaincase 5 Loosen do not remove the chaincase cover screws 6 Carefully pry the cover open NOTICE DO NOT insert a screwdriver or pry bar between the cover a...

Page 111: ...ecommended oil until the fluid begins to overflow Maximum fluid capacity is 10 5 oz 310 ml 11 Clean the area with a clean dry shop towel 12 Reinstall the fill plug Torque 4 4 9 ft lbs 5 4 6 6 Nm 13 Re...

Page 112: ...e recommended spark plugs with the proper gap Refer to the specifications section for the specific spark plug to be used in your snowmobile Use only resistor type spark plugs Torque spark plugs to 20...

Page 113: ...kit rotate the spark plug counter clockwise to remove it 4 Reverse the procedure for spark plug installation Torque to specification 5 Reinstall the spark plug cap Verify an audible click is heard wh...

Page 114: ...ce if debris or foreign material enters the fuel tank See your POLARIS dealer for service Contaminated or poor quality fuel may shorten the life of fuel system components and result in poor engine per...

Page 115: ...ance or repair replace the coolant with fresh Antifreeze 50 50 Premix Coolant Level The engine coolant level is controlled by the recovery system The recovery system components are Coolant bottle over...

Page 116: ...plugged or contains trapped air pockets Perform this procedure in a well ventilated area Use the recommended coolant See page 113 1 Open the side panels and remove the hood 2 Close the side panels WA...

Page 117: ...fast idle for several minutes until the heaters are warm to the touch Loosen the bleed screw occasionally to purge any trapped air 10 When all heater extrusions are warm to the touch stop the engine 1...

Page 118: ...cting 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 hoo...

Page 119: ...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...

Page 120: ...ure the brake pads do not drag on the disc and 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...

Page 121: ...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...

Page 122: ...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...

Page 123: ...g the same amperage rating of the blown fuse Never replace a fuse with a fuse of a higher amperage rating Constant Power Fuse Models equipped with electric start have a battery electric start wire har...

Page 124: ...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...

Page 125: ...emperatures remove the belt and warm it to room temperature Reinstall it before starting the snowmobile QUICKDRIVE Belt Condition if equipped Periodically check the condition of the QUICKDRIVE belt In...

Page 126: ...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...

Page 127: ...ard 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 han...

Page 128: ...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...

Page 129: ...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...

Page 130: ...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 r...

Page 131: ...rews to provide 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...

Page 132: ...s 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...

Page 133: ...ury or death See your POLARIS dealer Each week or before a long ride check the following items If component damage or loose fasteners are found see your POLARIS dealer for service Upper lower control...

Page 134: ...icle 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 Perfor...

Page 135: ...g Replacement 1 Raise and support the front of the snowmobile so the skis are approximately 6 inches 15 2 cm from the ground 2 Remove the attaching nuts and pry the skag downward 3 Remove the front en...

Page 136: ...hen reinstalling the battery always connect the negative black cable last Battery Removal 1 Remove the right side panel to access the battery See page 104 2 Remove the two plastic rivets 1 securing th...

Page 137: ...135 MAINTENANCE Battery if equipped Battery Removal 7 Remove the screw 4 securing the battery shield to the battery bracket 8 Remove the battery shield 5 9 Remove the battery from the battery bracket...

Page 138: ...e installing the battery 1 Ensure that the battery is fully charged 2 Set the battery in the battery holder 3 Place the battery shield on the battery bracket Install the screw to secure the shield Tor...

Page 139: ...interfere with the rear side panel tab Note the routing of the RED positive battery cable C and that the right fender D is pulled away from the chassis Item E is the constant power fuse connector 7 V...

Page 140: ...ach month during storage and recharge as needed to maintain a full charge Tip Battery charge can be maintained by using a POLARIS Battery TenderTM charger or by charging about once a month to make up...

Page 141: ...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 ba...

Page 142: ...e surface These products will buff the matte surface of the finish resulting in a glossy finish It is not recommended that you clean matte finishes with a pressure washer as this will further imbed co...

Page 143: ...ontainer 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...

Page 144: ...ches 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 S5108 6044 OS6P Displacement 599 cc Cylinders...

Page 145: ...ghter shift weights when operating in temperatures above 40 F 5 C Drive Clutch Bolt Torque 80 ft lbs 108 Nm Re torque after running engine 0 450 0 1500 10 64 1321585 Manual Start Black Green 7042083 E...

Page 146: ...RMK Brake Type Hayes Apollo Drive Clutch Center Distance 11 5 inches 29 cm Drive Belt P N 3211183 Drive Clutch P 85 Driven Clutch LW Team Roller Reverse Reverse Transmission Electronic Reverse Engine...

Page 147: ...000 6000 10 66 1321584 1800 2400 6000 8000 10 64 1321585 2400 3000 8000 10000 10 62 1321586 3000 3600 10000 12000 10 60 1321587 Clutching Chart ALTITUDE Meters Feet Drive Clutch Shift Weight Drive Clu...

Page 148: ...s 29 cm Drive Belt P N 3211183 Drive Clutch P 85 Driven Clutch LW Team Roller Reverse Reverse Transmission Electronic Reverse Engine and Cooling Engine S5202 8044 OS8P Displacement 794 cc Cylinders 2...

Page 149: ...Use 2 gram lighter shift weights when operating in temperatures above 40 F 5 C Drive Clutch Bolt Torque 80 ft lbs 108 Nm Re torque after running engine 0 600 0 2000 10 70 1322414 GOLD 701148 LH BLACK...

Page 150: ...78191 VES RACE 2 Cycle Engine Oil gal 3 8 l Chaincase Lubricants 2873105 SCL Synthetic Chaincase Lubricant qt 95 l 2873106 SCL Synthetic Chaincase Lubricant gal 3 8 l Grease Specialized Lubricants 287...

Page 151: ...drive belt Excessive belt sheave clearance SEE YOUR DEALER Drive belt turns over Wrong belt for application Replace the drive belt Clutch alignment out of spec SEE YOUR DEALER Engine mount broken or l...

Page 152: ...OUR DEALER Poor low RPM performance Worn drive belt Inspect and replace as needed Excessive belt sheave clearance SEE YOUR DEALER Sticky clutch SEE YOUR DEALER Poor fuel quality Use 87 91 octane fuel...

Page 153: ...ne lacks power Fouled or defective spark plug s Replace the plug s Fuel filter loss of high RPM power SEE YOUR DEALER Plugged fuel filter or tank pick up sock SEE YOUR DEALER Incorrect clutching SEE Y...

Page 154: ...way 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 D...

Page 155: ...oid 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 extremel...

Page 156: ...on page 64 Too little weight transfer when climbing Refer to the suspension adjustment and set up information beginning on page 64 Machine darts from side to side Check ski alignment see page 132 Make...

Page 157: ...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 informati...

Page 158: ...d by POLARIS including but not limited to Two year extended engine coverage Two year powertrain coverage Extended service contract See your dealer for details and separate terms and conditions for any...

Page 159: ...components use of aftermarket components unauthorized repairs repairs made after the warranty period expires or by an unauthorized repair center use of the product in competition or for commercial pur...

Page 160: ...AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION WHETHER ARISING OUT OF EXPRESS OR I...

Page 161: ...he selling dealer s authorized location as proof of residence Upon residence verification the servicing dealer will be authorized to perform the warranty repair If you move If you move to another coun...

Page 162: ...tside of the country where it was purchased and you have not followed the procedure set above your product will no longer be eligible for warranty or service bulletin coverage of any kind other than s...

Page 163: ...omponents of systems if their 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 Limite...

Page 164: ...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 structurall...

Page 165: ...r 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...

Page 166: ...164 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 167: ...3 115 Cooling System Bleeding 114 115 Customer Service 155 D Deep Lug Track Operation 89 Detonation Elimination Technology DET 44 45 Diagnostic Display Codes 102 103 Diagnostic Display Mode 61 Disable...

Page 168: ...8 Maintenance Recommendations 9 Maneuverability 24 Matte Finish Cleaning 140 Metric Standard Display 54 Mountainous Terrain Riding 14 21 N Noise 6 O Odometer Engine Hour Display 53 Oil Change Chaincas...

Page 169: ...6 Survival Preparation 12 Suspension Inspection Pre Ride 77 Suspension Lubrication Rear 105 Suspension Quick Set Up Guide 64 71 Switches Engine Stop Switch 92 Ignition Switch 34 Mode Select Buttons 48...

Page 170: ...For your nearest Polaris dealer call 1 800 POLARIS 765 2747 or visit www polaris com Polaris Industries Inc 2100 Highway 55 Medina MN 55340 Part No 9926021 Rev 02 Printed in USA...

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