Polaris Trail RMK Page 1 Owner'S Manual Download

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Pantone 426C

Trail RMK

Snowmobile Owner's Manual

for Maintenance and Safety

Summary of Contents for Trail RMK

Page 1: ...Pantone 426C Trail RMK Snowmobile Owner s Manual for Maintenance and Safety...

Page 2: ...ntone 426C For 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 9922282 Rev 01 Printed in US...

Page 3: ...ns 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 th...

Page 4: ...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 5: ...and quality of production components some minor discrep ancies may result between the actual vehicle and the information presented in this publi cation Depictions and or procedures in this publicatio...

Page 6: ...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 must be performed before riding...

Page 7: ...4...

Page 8: ...ll them in driver s training and safety courses sponsored by local or state organizations Follow the maintenance program outlined in this manual Preventive maintenance ensures that critical components...

Page 9: ...hat snowmobiles conform to prescribed sound levels Polaris snowmobiles are engineered to conform to these SAE standards Our muffler systems are designed to reduce noise levels and must not be altered...

Page 10: ...one of your existing keys so if both keys are lost the ignition switch must be replaced Vehicle Model Number ___________________________________________________ Tunnel VIN ___________________________...

Page 11: ...ith their meanings before reading the manual The safety alert symbol on your vehicle or in this manual indicates the potential for serious injury WARNING A WARNING indicates a potential hazard that ma...

Page 12: ...e operator safety Make sure your snowmobile is in excellent operating condition at all times We strongly rec ommend that the operator check major and vital safety components before every ride All Pola...

Page 13: ...ehind it while warming up the track A loose track or flying debris could cause serious injury or death We recommend having your dealer perform all track service and alignment procedures Stay Clear of...

Page 14: ...dio or cel lular telephone For added protection carry the following items on your snowmobile at all times Riding Position Operating a snowmobile requires skill and balance for proper control Rider pos...

Page 15: ...and Canada bear a U S Department of Transportation DOT label Approved helmets in Europe Asia and Oceania bear the ECE 22 05 label The ECE mark consists of a circle surrounding the letter E followed b...

Page 16: ...nowmobile opera tion 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 f...

Page 17: ...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 condi...

Page 18: ...ow 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 co...

Page 19: ...ice build up WARNING Ice and snow build up may interfere with the steering of your machine resulting in serious injury or death Keep the underhood area free of snow and ice Driving on Slippery Surface...

Page 20: ...hine to maintain proper balance and avoid possible roll over Slow down when reaching the crest of a hill Be prepared to react to obstacles sharp drops or other people or vehicles that may be on the ot...

Page 21: ...ed stops will also cause an overheated brake system This condition may lead to a sudden loss of brakes and or fire and may result in serious injury or death Clutch Guard Do not operate the engine with...

Page 22: ...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 a...

Page 23: ...ssive wear and damage to the slide rail track and or engine Do not drive for prolonged periods on blacktop gravel or ice If frequently operating in low cooling condi tions see your dealer for an optio...

Page 24: ...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 sp...

Page 25: ...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...

Page 26: ...he part number is printed on the decal Clutch Cover Warning This warning decal is found under the hood on the clutch cover WARNING Do not operate engine with hood open Do not attempt adjustment with e...

Page 27: ...ol 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...

Page 28: ...wear an approved helmet eye protection and adequate clothing while operating this vehicle This vehicle is designed for adult use only Check local laws for age requirements When operating with a passe...

Page 29: ...ude a fuel gauge 2 Ignition Switch 3 Brake Lever 4 Speedometer may include indicator warning lights 5 Reverse Indicator 6 Mountain Bar accessory 7 Engine Stop Switch see page 58 8 Throttle Control 9 C...

Page 30: ...ories are available from your Polaris dealer 1 Headlight Dimmer Switch 2 Parking Brake Lock 3 Handlebar Grip Warmer Switch 4 Thumbwarmer Switch 5 Electronic Reverse Button Fuel Valve The fuel valve is...

Page 31: ...3 Windshield 4 Handlebar 5 Operator Seat 6 Storage Compartment 7 Taillights 8 Snow Flap 9 Track 10 Suspension 11 Trailing Arm 12 Nosepan 13 Front Bumper do not use for pulling or dragging the snowmobi...

Page 32: ...with factory settings and then customizing each adjustment individually to suit rider preference The machine should be methodically tested under the same conditions after each adjustment trail and sno...

Page 33: ...et is called spring preload For the best ride the spring preload should be set as low as possible to use the full travel of the ski shock with occasional light bottoming To determine if your machine i...

Page 34: ...prings For models without externally adjustable or revalvable shocks the front springs can be changed if spring preload alone isn t sufficient and fur ther adjustment is desired to control suspension...

Page 35: ...ct the han dling of the snowmobile and the per formance of the suspension Never exceed one inch of preload beyond the factory settings and ensure that both sides are adjusted the same When decreasing...

Page 36: ...n at which the spring pre load should be set However this may vary with riding style With a little experimentation each rider can find a preferred set up These adjustments are easy to make involve ver...

Page 37: ...on at full extension This is measurement X Take the first measurement with no rider and with the rear suspension at full extension Tip The rear bumper may need to be lifted upward slightly to fully ex...

Page 38: ...ue arm Use the illustration for ref erence The ideal amount of Sag for the this rear suspension is four inches X Y 4 If the rear suspension rides in less than three inches or more than five inches wit...

Page 39: ...ur set up may vary based on your desired riding style Limiter Strap Position The following information is pro vided only as a guideline to be used for initial suspension set up Your set up may vary ba...

Page 40: ...g further adjustments Tip An excessive adjustment can result in damage to the shock When adjust ing these shocks we recommend that you turn the screw only 1 2 turn at a time then test ride 3 Adjust th...

Page 41: ...e handlebar either left or right for access to the rear nuts If necessary pry the blocks apart with a screw driver 3 Adjust the handlebar to the desired angle Be sure the handlebar brake lever and thr...

Page 42: ...Polaris parts and accessories on your Polaris snowmobile Use of unapproved parts and accessories may result in Non compliance with government industry requirements Voiding of warranty Personal injury...

Page 43: ...ine with traction products be aware of the laws in your area pertaining to the use of traction products Track studding will enhance braking control on hard packed snow or ice but extreme caution is st...

Page 44: ...and skags n 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 balance and vehi...

Page 45: ...udding chart for recommended traction accessories NOTICE Never add shims to the wear strip Track damage will result due to lack of clearance between upper carrier wheels and track Components as viewed...

Page 46: ...ring System 47 Recoil Rope 47 Parking Brake Lock Brake Lever Brake System 45 46 81 Auxiliary Shut Off Switch Engine Stop Switch 58 Ignition Switch 48 Taillight Brakelight Headlight 48 Suspension Mount...

Page 47: ...the Owner s Manual completely and refer to it often The manual is your guide to safe and enjoyable snowmobiling experience n Throttle Lever The throttle and brake are the primary controls of your snow...

Page 48: ...stance indi cates low brake fluid level or air in the hydraulic system See pages 82 83 or see your dealer for service Lever Feel If the brake lever feels spongy when squeezed check the brake fluid lev...

Page 49: ...ghtly enough the lock will move freely into place Do not force the lock or it may break The brake light will illuminate if the parking brake lever lock is set while the engine is running It will also...

Page 50: ...he possibility of track damage and or failure Driving at high speeds for extended periods of time with inadequate lubrication could severely damage track rods break track edges and cause other track d...

Page 51: ...ck the headlight high and low beam taillight and brake light Replace burned out lamps before operating n Mirrors if equipped Adjust the mirrors so they can be used to their full advantage n Operating...

Page 52: ...age do not operate the electric starter or pull rope starter while the engine is running 5 If equipped with electric start turn the key to START to crank the engine Release the key to the ON position...

Page 53: ...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 54: ...Oil Recommendations Engine lubrication comes from oil added to the fuel and oil injection systems Polaris recommends the use of Premium 2 Cycle Oil for this engine See page 109 for the part numbers of...

Page 55: ...ne and the moving track Never hold the snowmobile up or stand behind it while warming up the track Do not use excessive throttle during warm up or when the track is free hanging Be sure the rear suppo...

Page 56: ...ea 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 refu eling is performed or where...

Page 57: ...l Reserve Capacity Mechanical Gauge There are approximately two gallons of fuel left in the tank when the mechanical fuel gauge reads RES Fuel System Deicers If you use non oxygenated fuel Polaris rec...

Page 58: ...loss of pumping action which could result in engine damage This is especially important when the machine is operated in mountainous ter rain Always check the oil level when refueling When the oil reac...

Page 59: ...ailure 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 be caused by things like fuel line restricti...

Page 60: ...r altitude range The main jet installed in production is not correct for all altitudes and or temperatures NOTICE A main jet that s too small will cause a lean operating condition and may cause seriou...

Page 61: ...n WARNING Operating the snowmobile with a faulty throttle 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 dur...

Page 62: ...e 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 E...

Page 63: ...stem This overheated condition could cause sudden loss of brakes and or fire resulting in serious injury or death When traveling on long downhill stretches pump the brakes Riding the brakes may cause...

Page 64: ...o 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 Engaging Reverse 1 Stop...

Page 65: ...e instrument panel will shut off 3 Apply the throttle slowly to make sure the transmission is in for ward Ignition Altitude Setting At higher altitudes above 6000 feet the engine will require a differ...

Page 66: ...d 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...

Page 67: ...is intended solely for your use in making a purchasing decision Emission Control Maintenance Requirements Your snowmobile is certified to operate on gasoline with a minimum octane level of 87 R M 2 I...

Page 68: ...rvals 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 perio...

Page 69: ...Clean R Replace 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 Offset Alignment without belt 86 I I I Drive Belt Condition 87...

Page 70: ...e Pads 81 I I I I Brake Disc I I I I Parking Brakes 46 I I I I Brake System 45 81 I Brake fluid 82 R FUEL MANAGEMENT Pilot Air Screws I I I Carburetor synchronize 56 I I I Idle RPM I I I Throttle Leve...

Page 71: ...I Brakelight 48 I I I I I Headlight 48 I I I I I CHASSIS Ski Toe Alignment I I I Suspension Mounting Bolts I I I I I Steering Fasteners I I I I C Rear Suspension Fasteners I I I I I Suspension Shock...

Page 72: ...equency 150 mi 240 km 500 mi 800 km 1000 mi 1600 km 2000 mi 3200 km Pre Season CHASSIS Rear Suspension Pivot Shafts 71 L L L Camber Alignment I I I Radius Rod Bushings I Handlebar Centering I Track Al...

Page 73: ...or fitting Grease the left and right spindles Raise the front end of the machine to permit better grease entry into the spindle area Lubricate both of the front ski pivots at the fittings as shown Gr...

Page 74: ...1000 miles 1600 km 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 lubri...

Page 75: ...ptor until grease purges from inside or outside the bearing seal approximately two pumps Throttle Cable Lubricate the throttle cable lightly with grease or oil With the engine off turn the handlebars...

Page 76: ...evel between the safe marks on the dipstick Clean the magnetic plug on the dipstick whenever checking or changing oil Polaris recommends the use of Polaris Synthetic Chaincase Lube See page 109 for th...

Page 77: ...manner This selection could cause the customer who normally operates the engine under medium or light duty to have spark plug failure NOTICE A spark plug with a heat range too high will always cause e...

Page 78: ...n deposits The electrodes are not burned or eroded This indi cates the proper type and heat range for the engine and the service The tip should not be white A white insulator tip indicates overheating...

Page 79: ...odically to remove any accumulation of snow NOTICE Operating the snowmobile with the intake filters removed may cause carburetor icing The result will be poor fuel economy or carburetor malfunction Al...

Page 80: ...ays work in a well ventilated area away from anything that may cause the fuel to ignite such as open flames sparks heaters trouble lights cigarettes etc Review the gasoline warnings found on page 53 P...

Page 81: ...engine damage Have your Polaris dealer perform all carburetor adjustments to ensure all adjustments are done correctly Carburetor Adjustments The frequency at which the carburetors are synchronized or...

Page 82: ...r damaged fuel lines promptly NOTICE Kinking the fuel lines or using a pliers or similar tools to remove fuel lines may cause damage to the lines If a fuel line has been damaged or kinked replace it p...

Page 83: ...e time for the exhaust system to cool Never perform this procedure with the engine running Drive Chain Tension To obtain correct chain tension 1 Rotate the driven clutch coun terclockwise to move all...

Page 84: ...ealer WARNING Brake failure during operation can result in serious injury or death Properly functioning brakes are vital to your safety Be sure the brake pads do not drag on the disc and that brake le...

Page 85: ...sight glass in the brake reservoir If the fluid is sufficient the sight glass will be black If the sight glass is any color other than black add brake fluid Keep the master cylinder cover free of dir...

Page 86: ...ket 2 Fill the master cylinder reservoir to between the MIN and MAX marks or 1 4 5 16 inch 6 8 cm below the lip of the reservoir opening Reinstall the gasket and cover 3 Slip a rubber tube over the ba...

Page 87: ...adlight 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 aimed two 2 inches 5...

Page 88: ...rom the spring retainer 2 Lift spring carefully around wire harness 2 and flip to out side of housing 3 With the wire harness attached to the bulb 3 withdraw bulb from housing 4 Grasp bulb by metal ba...

Page 89: ...ust be performed by an authorized Polaris dealer Any unauthorized modifications to clutches such as adding or remov ing weights will void the warranty The bushings in the weights and rollers of Polari...

Page 90: ...bleshooting on page 111 Periodically check the condition and tension of the drive belt and always carry a spare Inspect the belt for signs of excessive wear frayed edges missing cogs cracks and excess...

Page 91: ...ly 3 Lock the parking brake if equipped 4 Open the hood 5 Remove the clutch guard retain ing pin and open the clutch guard 6 Rotate the driven clutch counter clockwise 1 4 turn by hand to ensure forwa...

Page 92: ...heaves as outlined in 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...

Page 93: ...s measurement should be 1 1 4 inches 32 mm Drive Belt Adjustment Belt deflection should be adjusted without removing the clutch from the jackshaft 1 Loosen the 7 16 inch jam nut on the belt width adju...

Page 94: ...the engine case Adjust if necessary and lock the jam nut Tool Kit A tool kit is included with each machine for emergency and rou tine maintenance Always keep the tool kit with the snowmobile Chain Ten...

Page 95: ...r operate with a damaged track Never rotate a damaged track under power 1 Using a hoist safely lift and support the rear of the snowmobile off the ground 2 Rotate the track by hand to check for possib...

Page 96: ...e little or no snow for lubrication The slide rail requires adequate snow cover for sufficient lubrication Excessive wear indicates insufficient lubrication A new rail slide can cause faster heat buil...

Page 97: ...cause serious damage to the snowmobile which can result in loss of vehicle control and serious injury or death Always maintain the track tension as specified 1 Turn the engine off 2 Lift the rear of t...

Page 98: ...measure ment on the other side of the track Tip Check more frequently when machine is new 10 Start the engine and slowly rotate the track at least five revolutions Let the track come to a stop do not...

Page 99: ...st five complete revolutions 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...

Page 100: ...MAINTENANCE Steering System Steering Inspection Each week or before a long ride check fasteners and tighten if neces sary Specific fasteners that should be checked are marked with a in the illustrati...

Page 101: ...aler 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 measureme...

Page 102: ...hicle control may result causing serious injury or death Replace skags as recommended Check skags weekly to maintain positive steering characteristics Skags must be replaced when worn to half their or...

Page 103: ...down time Before beginning any snowmobile trip a visual inspection will uncover potential problems Check the follow ing items on a weekly basis or before any long trip n Check suspension mounting bolt...

Page 104: ...l attention Batteries produce explosive gases Keep sparks open flames cigarettes etc away Ventilate when charging or using in closed space Always shield eyes when working near batteries Battery Fluid...

Page 105: ...ry cables can result in an explosion and cause serious injury or death When removing the battery always disconnect the negative black cable first When reinstalling the battery always connect the negat...

Page 106: ...installed Route the vent tube properly to prevent kinks and to allow for proper drainage WARNING Batteries contain gases that can explode If the battery vent tube is pinched or kinked battery gases co...

Page 107: ...Store it in a cool dry place Check and or charge monthly Have the battery tested and recharged before reinstalling it in the vehicle If a battery with a low charge freezes the cells could be damaged...

Page 108: ...ace and support it at the rear with an appropriate track stand The track should be suspended approximately 4 inches 10 cm off the ground Remove the key and cover the machine Tip Polaris has accessory...

Page 109: ...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 instruction...

Page 110: ...5 Pour approximately two ounces of Polaris injector oil into the spark plug hole 6 Wait one to two minutes and perform steps 3 to 5 on remaining cyl inders 7 Replace the spark plugs and lower the mach...

Page 111: ...edges steering linkage moving parts and hot exhaust parts Battery Always prepare and maintain the battery as outlined on page 101 Track and Suspension Moderate track tension should be maintained duri...

Page 112: ...Oil 2 5 gal Chaincase Lubricants 2873105 Synthetic Chaincase Lubricant qt 2872951 Synthetic Chaincase Lubricant 12 oz Grease Specialized Lubricants 2871312 Grease Gun Kit Premium All Season 3 oz 28713...

Page 113: ...sion spring blocks or install optional torsion springs to achieve correct sag dimensions Move limiter strap on front torque arm to low position see page 36 Front end pushes Check for worn skags Check...

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: ...rance and replace if neces sary SEE YOUR DEALER Harsh drive clutch engage ment Drive belt worn or too narrow Replace drive belt Excessive belt sheave clearance SEE YOUR DEALER Drive belt turns over Wr...

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

Page 117: ...ed Poor engine compression Running too lean a mixture too small a main jet will cause seizure resulting in loss of power SEE YOUR DEALER This indicates a major engine problem that must be repaired bef...

Page 118: ...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 followi...

Page 119: ...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 mode...

Page 120: ...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 121: ...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 deale...

Page 122: ...verage 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 he...

Page 123: ...overage is automatic with no addi tional paperwork required The free Second Year Engine Service Contract is subject to a 50 deductible per visit Regular documented service maintenance visits are requi...

Page 124: ...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 125: ...omponents 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...

Page 126: ...ue 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 compet...

Page 127: ...r 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...

Page 128: ...125 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 129: ...126 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 130: ...127 MAINTENANCE LOG DATE MILES KM TECHNICIAN SERVICE PERFORMED COMMENTS...

Page 131: ...ce 86 Clutch Cover Warning 23 Clutch Guard 18 Clutch System 86 91 Clutches 19 Cold Weather Drive Away 19 D Disabled Operators 13 Drive Belt Safety 18 Adjustment 90 Condition 87 Deflection 90 Installat...

Page 132: ...ncase 73 Oil Recommendations 51 Operating in Deep Snow 20 Operation Warning 25 P Parking Brake Lever Lock 46 Passenger Warning 23 Periodic Maintenance Table 66 69 Polaris Products 109 Pre Ride Checkli...

Page 133: ...Throttle Safety Switch 44 58 Tool Kit 91 Torque Stop 91 Torsion Spring Preload 36 Towing 63 T Track Alignment 96 Cooling 53 Damage 47 Inspection 92 Lubrication 93 Tension 33 94 95 Warm Up 52 Track Se...

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Polaris Trail RMK, Owner'S Manual

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