Polaris 800 PRO-RMK 2011 Owner'S Manual Download Page 80

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MAINTENANCE

Lubrication

Driveshaft Bearing

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.

Summary of Contents for 800 PRO-RMK 2011

Page 1: ...ile are not 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 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: ...The text is printed on 100 recycled with 40 post consumer waste PCW ...

Page 4: ...r your nearest Polaris dealer call 1 800 POLARIS or visit www polarisindustries com Polaris Sales Inc 2100 Hwy 55 Medina MN 55340 Phone 1 888 704 5290 Part No 9922844 Rev 01 Printed in USA 9922844 PMS 419 ...

Page 5: ...esign and development of your POLARIS vehicle making it the finest machine we ve ever pro duced 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 information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory c...

Page 6: ...etween the actual vehicle and the information presented in this publi cation 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 Eng...

Page 7: ...controls and features The Perfect Fit 42 This section includes suspension set up information and explains how to make additional suspension adjustments for the perfect riding experi ence Pre Ride Inspections 48 This section explains procedures that must be performed before riding Operation 55 This section explains proper engine break in operation of features and general operating procedures Mainte...

Page 8: ...4 ...

Page 9: ... 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 Ma...

Page 10: ...hat snowmobiles conform to prescribed sound levels POLARIS snowmobiles are engineered to conform to these SAE stan dards 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 manufac turing quieter...

Page 11: ...S 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 H right side of tunnel ________________________________________________ Engine Serial Number on recoil housing ____________________________________________ Key Number ____________________________________...

Page 12: ...heir meanings before reading the manual The safety alert symbol indicates a potential personal injury hazard WARNING A WARNING indicates a hazardous situation which if not avoided may result in death or serious injury CAUTION A CAUTION indicates a hazardous situation which if not avoided may result in minor or moderate injury NOTICE A NOTICE indicates a situation that may result in property damage...

Page 13: ... 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 aerod...

Page 14: ... off the igni tion 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 15: ...r will also be displayed on the label Eye Protection Do not depend on eyeglasses or sunglasses for eye protection When ever riding a POLARIS vehicle always wear shatterproof goggles or use a shatterproof helmet face shield POLARIS recommends wearing approved Personal Protective Equipment PPE bearing markings such as VESC 8 V 8 Z87 1 or CE Make sure protective eye wear is kept clean Clothing Be pre...

Page 16: ...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 condi tions you may encounter Such equipment may include but is not lim ited 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 cel lular telephone Always carry the owner s manual on y...

Page 17: ... 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 18: ...lf 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 suffi ciently 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 19: ...now 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 moun tainous terrain Before riding in mountainous terrain call or log on to your local ava lanche advisory to get current weather and snow stability information Fo...

Page 20: ...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 21: ... 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 22: ...omplex mechanism that rotates at high speeds Each clutch is dynami cally balanced before installation Any tampering may disrupt this preci sion balancing and create an unstable condition Cold Weather Drive Away Whenever your snowmobile has been parked for a length of time espe cially overnight always make sure the skis and track are loosened from ice and snow before attempting to drive Apply the t...

Page 23: ...well 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 pro tection under normal riding conditions Your sn...

Page 24: ... 93 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 KPH 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...

Page 25: ...rchase a replacement Replacement safety labels are pro vided 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 c...

Page 26: ...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 27: ...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 28: ...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 vehi cle 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 29: ...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 30: ...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 31: ...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 32: ... accessories for your snowmobile to help make each ride more enjoyable Use only POLARIS parts and accessories on your POLARIS snowmo bile 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 Exhaus...

Page 33: ...must be connected Whenever in doubt of your fuel purchase use the 10 ETHANOL 24 OHM resistor as a safeguard The resistor is installed into the wiring harness on the left side of the snowmobile just above the top of the oil bottle see photo NOTICE Engine damage may occur if ethanol fuel is used while the non etha nol fuel resistor is installed The check engine light may also display in this conditi...

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: ...non ethanol fuel resistor installed Verify correct fuel resistor for fuel type in tank Low fuel no fuel in tank Refuel with recommended fuel Water in fuel Replace with recommended fuel Plugged fuel filter or tank pick up sock See your POLARIS dealer for service Alcohol based fuel additive used with Ethanol fuel Do not add deicers or additives that contain any form of alcohol while using up to 10 E...

Page 36: ... handlebar or console NOTICE Certain products will damage the lens and other plastic sur faces 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 Temperature Indicator Park Brake Indicator Reverse Indicator MODE Button SELECT Button M...

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 recom mended oil before further operation See page 61 High Beam Indicator The high beam indicator illuminates when the lights are set to high b...

Page 38: ...ttable trip meters 2 total engine hours of operation fuel level engine tempera ture and diagnostic display mode Setting changes must be made with the engine running or with the vehi cle 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 38 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 37 5 Battery Power This ind...

Page 40: ...splays first make sure the information dis play 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: ...d 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 second...

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: ...ive 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 fol lowing 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 44: ...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 45: ...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 Injec tion Supply PWR Voltage Too High 3598 ...

Page 46: ...this adjustment first 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 Spring Type Maximum Installed Length MinimumInstalled Length RMK Factory Spring 10 3 4 27 3 cm 9 5 8 24 5 cm PRO RMK Factory Spring 11 28 cm 9 3 4 24 8 cm ASSAULT RMK Factory Spring 11 28 cm 9 3 8 23...

Page 47: ...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 48: ...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 s...

Page 49: ...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 incre ments then test ride When adjusting the front suspension always adjust both clickers equally To stop bottoming of the front or rear sus pension stiffer ride rotate the clicker s clockwise two clicks as viewed from the top ...

Page 50: ...ce is RTSS preload Perform this adjustment first See page 42 After adjusting the preload and if desired additional adjustments can be made to the independent front suspension and front track shock preload When adjusting the front suspension be sure the springs on both sides of the vehicle are at the same adjustment For a softer ride on rough washboard surfaces reduce front track shock FTS spring p...

Page 51: ...st the handlebar forward or rearward to the desired position 3 Tighten the bolts Handlebar Angle 1 Loosen the four bolts on the top of the adjuster block If necessary pry the blocks apart with a screwdriver 2 Adjust the handlebar forward or rearward to the desired angle 3 Tighten the bolts Loosen top bolts to adjust handlebar angle Loosen bottom bolts to adjust handlebar position if equipped ...

Page 52: ...1 Steering System 53 Recoil Rope 53 Coolant Level 81 Chaincase Oil Level 75 Injection Oil Level 61 Parking Brake Lock Brake Lever Brake System 51 52 86 Auxiliary Shut Off Switch Engine Stop Switch 54 Ignition Switch 54 Headlight Taillight Brakelight 54 Suspension Mounting Bolts 49 Skags Wear Bars 101 Ski Saddle and Spindle Bolts 49 Hood and Side Panel Fasteners 73 Throttle Lever Safety Switch 62 6...

Page 53: ...ems Check the follow ing 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 97 Check rear idler adjusting bolt locknuts for tightness Check front torque arm limiter strap condition Check rail slide condition 101 Check track tension 96 Check ski runner skag condition 101 Check ski spindle bolts for t...

Page 54: ...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 55: ...tes low brake fluid level or air in the hydraulic system Refer to the brake bleeding infor mation on page 88 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 87 WARNING Continued use of spongy brakes may cause a complete loss of brakes which could result in serious injury or death Always h...

Page 56: ...ce 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 tight...

Page 57: ...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 58: ... 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 59: ...tle no more than 1 4I open while cranking the engine When the engine starts immediately release the throttle CAUTION To avoid injury and or engine damage do not operate the electric starter or pull rope starter while the engine is running NOTICE Operating the vehicle immediately after cold starting could cause engine damage Allow the engine to warm up for several minutes before operating the vehic...

Page 60: ...numbers of POLARIS 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 sep...

Page 61: ...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 snow mobile Oil Injection System Always check and fill the oil bottle when refueling See page 61 NOTICE Serious engine damage can occur without the proper lubrication Check the oil bottle level often during the first tank of fuel If the oil level doesn ...

Page 62: ...iate stand to securely support the rear of the snow mobile at the rear bumper The track should be about 4I 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 the ...

Page 63: ...in or near the area where refu eling 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 64: ...ed 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 deicers or add...

Page 65: ...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 refu eling Add oil as needed The oil bottle cap is vented to allow proper oil flow See your POLARIS dealer for recommended replacement p...

Page 66: ... safety 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...

Page 67: ...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 68: ...idle 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 69: ...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 70: ...y See page 62 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 71: ...ow 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 an...

Page 72: ...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 avail able to your qualified service technician Reverse if equipped must not be engaged during engine tune ups Owne...

Page 73: ...ervals All necessary replacement parts and labor incurred with the exception of authorized warranty repairs become the responsibility of the regis tered 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 74: ...L Lubricate Item 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 90 I I I Drive Belt Condition 91 I I I I Clutches 90 C C C Belt Tension I I I I Clutch Sheaves 90 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 BTDC I I I VES Syst...

Page 75: ... I I I I Brake System 51 86 I Brake Fluid 87 R FUEL MANAGEMENT Idle RPM I I I Throttle Lever 63 I I I I I Oil Pump Lever synchronize I I I Throttle Position Sensor I I I Fuel Lines 77 I I I I Fuel Filter 77 EVERY 2000 3200 or EVERY 2 YEARS Oil Filter 80 R R Oil Lines 80 I I I Air Box I I I I I ELECTRICAL Auxiliary Shut Off Switch 54 I I I I I Throttle Safety Switch 62 I I I I I Ignition Switch I I...

Page 76: ...I Steering Fasteners I I I I C Suspension Shock Oil R Cooling Fins and Shroud I I I I Drive Shaft Bearing 76 L L L I Skags Wear Bars 101 I I I I I Ski Saddle Spindle Bolts I I I I I Drive Chain Tension 85 I I I I I Hood and Side Panel Fasteners 73 I I I I I Rear Wheel Idler Bolts 97 I I I I I Idler Bolt Jam Nut 97 I I I I I Camber Alignment I I I Handlebar Centering I Tether Switch and Strap 54 I ...

Page 77: ...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 78: ...ned in the Periodic Maintenance Table beginning on page 70 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 sus pension For more information about suspension lubrication and adjust ments see your POLARIS dealer H H H ...

Page 79: ...an 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 ...

Page 80: ...tion Driveshaft Bearing 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 ...

Page 81: ...oor quality 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 conditio...

Page 82: ...hange the spark plugs every 2000 2500 miles 3200 4000 km 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 damage if the engine is operated in conditi...

Page 83: ... Reverse the procedure for spark plug installation Torque to specifi cation 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 indi cates the proper type and heat range for the engine and the service TIP The tip should not be white A white insulator ti...

Page 84: ...00 miles 1600 km Oil Filter The oil filter is located at the side of the oil tank Have your dealer change the oil filter and bleed the system annually or every 1000 miles 1600 km TIP The direction of the arrows indicates the direction of flow through the fil ter ...

Page 85: ...re See page 104 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...

Page 86: ...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 87: ... 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 pan els are securely in place before starting the engine 8 ...

Page 88: ...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 73 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 89: ... 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 90: ...ing brakes are vital to your safety Be sure 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 16I Brake Components 1 Brake Caliper 2 Brake Disc 3 Brake Pad Material Replace when thickness is less than 1 16I 1 5 mm 4 Anti rattle springs come with brake pad k...

Page 91: ...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 92: ...et 2 Fill the master cylinder reservoir to between the MIN and MAX marks or 1 4 5 16I 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 valve...

Page 93: ...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 94: ...epairs 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 lubri cate clutch bushings Clutch Alignment Offset Clutch ali...

Page 95: ... cracks and excessive looseness Replace the belt if any of these conditions exist See Drive Belt Troubleshooting on page 109 Always carry a spare drive belt Store the spare belt in the belt clip located under the left side of the hood For improved drive away during extremely cold temperatures remove the belt and warm it to room temperature Reinstall it before starting the snowmobile ...

Page 96: ...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 clock wise to increase the distance between the sheaves or outward counter clockwise to decrease the distance 3 Tighten the jam nut 1 2 ...

Page 97: ...tion 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 open far enough to remove the ...

Page 98: ...e install belts so they operate in the same direction of rotation by positioning the identification numbers so that you can read them If required separate the sheaves as out lined in the belt removal procedures 3 Turn the driven clutch moveable sheave clockwise while pushing inward and forcing the belt down between the sheaves 4 Hold the belt down between the sheaves and roll the bottom portion ov...

Page 99: ...il 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 op...

Page 100: ...sion and 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 TE...

Page 101: ...de equal adjust ment 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 98 and adjust as necessary 12 Tighten the locknuts 13 Tighten the idler shaft bolts 14...

Page 102: ...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 H 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 lockn...

Page 103: ...99 MAINTENANCE Steering System Steering Inspection Each week or before a long ride check all steering system fasteners and tighten if necessary ...

Page 104: ... dealer With the handlebars in a straight ahead position and with vehicle weight compressing the suspension measure from the straight edge of the skis at the center of the ski mounting bolt The measurement between the skis at point X should be 1 8I to 1 4I 3 6 mm greater than the measurement at point Y TIP If the skis are misaligned we recommend that your dealer correct the align ment since camber...

Page 105: ... their orig inal 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 6I 15 2 cm from the ground 2 Remove the attaching nuts and pry the skag downward 3 Remove the front end of the skag 4 Remove the rear end of the skag 5 Reverse the steps to install a skag Rail Slide Wea...

Page 106: ...ventive measures to aid against deterioration and to prolong the useful life of many components See page 104 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 107: ...of more than 60 days the engine must be fogged with fogging oil Follow the engine fogging instructions provided on the container Always add Premium 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 o...

Page 108: ...cle Engine Oil 4 ltr Chaincase Lubricants 2873105 Synthetic Chaincase Lubricant qt 95 l 2872951 Synthetic Chaincase Lubricant 12 oz 355 ml Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 89 ml 2871322 Premium All Season Grease 3 oz 89 ml cartridge 2871423 Premium All Season Grease 14 oz 414 ml cartridge 2871329 Dielectric Grease Nyogelt Coolant 2871323 Anitfreeze 60 40...

Page 109: ... drive belt Excessive belt sheave clearance SEE YOUR DEALER Drive belt turns over Wrong belt for appli cation Replace the drive belt Clutch alignment out of spec SEE YOUR DEALER Engine mount bro ken or loose Inspect and replace SEE YOUR DEALER Machine fails to move Clutch jammed Check for twisted belt or broken spring SEE YOUR DEALER Track jammed Foreign object may be caught or the rail slide melt...

Page 110: ...YOUR 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 or higher Engine doesn t turn Seized engine SEE YOUR DEALER Seizure is a result of poor lubrication inade quate fuel supply broken parts or improper cooling Hydrostatic lock Fuel may have entered the...

Page 111: ...e 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 Plugged fuel filter or tank pick up sock SEE YOUR DEALER Incorrect clutching SEE YOUR DEALER Engine continually backfires Faulty plug s Change plug s Fuel System Dirt or ice may be in the fuel system deicer should be added to non etha nol fuel at all...

Page 112: ...on page 42 Too little weight transfer when climbing Refer to the suspension adjustment and set up information beginning on page 42 Machine darts from side to side Check ski alignment see page 100 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 b...

Page 113: ...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 114: ...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 fol lowing information 1 Serial number 2 Model number 3 Dealer name 4 Date of purchase 5 Details of trouble experienced 6 Length of time and conditions of operation 7 Previous correspondence Use the page pro...

Page 115: ...e owner reports theft A In addition to notifying the proper law enforcement officials the owner must call POLARIS Customer Service B Owners must provide their name address telephone number and the model and serial number of stolen machines 2 POLARIS warranty will provide all dealerships with a monthly updated list of all stolen units to further monitor thefts 3 POLARIS warranty will aid in notifyi...

Page 116: ...tal 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 pur poses other than for which it was manufactured The warranty does not cover any dam ages that occur during trailer transit or as a result of unauthorized service or parts In addition this warrant...

Page 117: ...t 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 you may use any POLARIS Servicing Dealer to perform warranty service Please work with your dealer to resolve any warranty issues Your dealer will contact the appropriate personnel at POLARIS...

Page 118: ... coverage 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 contami...

Page 119: ...m 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 120: ...ou 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 war ranty or service bulletin coverage of any kind other than safety bulletins Vehicles reg istered to Government officials or military personnel on assig...

Page 121: ... components of systems whose only purpose is to control emissions Repairing or replacing other components not covered by this war ranty 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 followi...

Page 122: ...d by a defect in material or workman ship 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...

Page 123: ...er each time your snow mobile is serviced This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 3200 km ...

Page 124: ...120 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 125: ...121 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS ...

Page 126: ...lay Codes 40 41 Diagnostic Display Mode 39 Disabled Operators 12 Display Standard Metric 38 D Drive Belt 18 Drive Belt Break In 57 Drive Belt Adjustment 92 Drive Belt Condition 91 Drive Belt Deflection 92 Drive Belt Installation 94 Drive Belt Removal 93 Drive Chain Tension 85 Driver Awareness 14 Driveshaft Bearing Lubrication 76 Driving Downhill 17 Driving in Hilly Terrain 17 Driving on Slippery S...

Page 127: ... Headlight Replacement 89 Taillight Brake Light 89 Lubrication 74 76 Rear Suspension 74 M Maintenance Interval Table 70 72 Maintenance Program 69 Maintenance Recommendations 9 Maneuverability 18 Metric Standard Display 38 N Noise 6 O Odometer Engine Hour Display 37 Oil Change Chaincase 75 Oil Filter 80 Oil Injection System 57 Oil Level Chaincase 75 Oil Level Injection 61 Oil Lines 80 Oil Recommend...

Page 128: ...torage Bag Under Seat 28 Storage Procedures 102 103 Storage Daily 67 Storage Tools 28 Survival Preparation 12 S Suspension Adjustments 42 46 Suspension Inspection Pre Ride 49 Suspension Lubrication Rear 74 Suspension Set Up Fine Tuning 44 Switches Engine Stop Switch 62 Mode Select Buttons 32 Mode Set Switch 32 Throttle Safety Switch 62 T Taillight Brakelight Replacement 89 Throttle Lever 63 Thrott...

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Polaris 800 PRO-RMK 2011, Owner'S Manual

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