Polaris RMK Shift Owner's Manual
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Polaris RMK Shift Owner's Manual

Polaris RMK Shift Owner's Manual

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Pantone 280 CVC
RMK Shift
600 RMK
700 RMK
700 Dragon RMK
800 Dragon RMK
Snowmobile Owner's Manual
for Maintenance and Safety

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  • Page 1 Pantone 280 CVC RMK Shift 600 RMK 700 RMK 700 Dragon RMK 800 Dragon RMK Snowmobile Owner's Manual for Maintenance and Safety...
  • Page 2 Pantone 280 CVC 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. 9921554 Rev 01 Printed in USA...
  • Page 3 WARNING Read, understand, and follow all of the instructions 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 contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
  • Page 4 • RANGER utility vehicles • Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre- ational vehicles manufactured in the world today. Many years of experi- ence have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we’ve ever produced.
  • Page 5 POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus- tries Inc. Copyright 2007 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant...

  • Page 6: Table Of Contents

    Polaris Products..... . . 112 Troubleshooting ..... . . 113 Warranty .

  • Page 8: Introduction

    INTRODUCTION Important Notes for Owners and Drivers After reading this manual, store it in the snowmobile for convenient ref- erence. It should remain with the snowmobile when the snowmobile is sold. Some of the illustrations and photos used in this manual are general rep- resentations.
  • Page 9 Polaris snowmobiles are engineered to conform to these SAE standards. Our muffler systems are designed to reduce noise levels and must not be altered or removed. The sound of your snowmobile may not be welcome to non-snowmobilers, so you have a responsibility to operate your snowmobile with concern for others.
  • Page 10 Remove the spare key and store it in a safe place. An ignition key can be duplicated only by ordering a Polaris key blank (using your key num- ber) and mating it with one of your existing keys. The ignition switch must be replaced if all keys are lost.

  • Page 11: Safety

    SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol, on your vehicle or in this manual, alerts you to the potential for injury.
  • Page 12 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.
  • Page 13 SAFETY Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. WARNING Serious injuries may result if hands, feet, or clothing become entangled in the track. Be alert when riding, and remain properly seated to stay clear of the track.
  • Page 14 SAFETY Operator Safety Riding Position Operating a snowmobile requires skill and balance for proper control. Rider positions may vary with experience; but under many conditions, the proper position is to be seated with both feet on the running boards and both hands on the handlebar grips for proper throttle, brake and steering control.
  • Page 15 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.
  • Page 16 Operators with cognitive or physical disabilities have an increased risk of loss of control, which could result in serious injury or death. Do not allow disabled persons to operate this vehicle. Rider Capacity Your Polaris snowmobile is designed for a single rider only. Do not carry a passenger. Excessive Speed WARNING High speed driving, especially at night, could result in serious injury or death.
  • Page 17 SAFETY Operator Safety Driver Awareness Slow down when traveling near poles, posts, or other obstacles. Be especially alert if you’re snowmobiling after dark. Always be on the alert for wire fences. Single strands are especially dangerous, since there may be a great distance between posts.
  • Page 18 SAFETY Operator Safety Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain: • Take an avalanche class • Travel with experienced people • Travel on designated trails • Make sure each person is equipped with a shovel, probe and avalanche beacon.
  • Page 19 SAFETY Operator Safety Ice and Snow Build-up WARNING Ice and snow build-up may interfere with the steering of 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 interfering with full left and right steering.
  • Page 20 SAFETY Operator Safety Driving on Slippery Surfaces WARNING Never attempt an abrupt change of direction when operating on slippery sur- faces. Proceed slowly and use extra caution. Driving on ice or hard-packed snow reduces steering and braking control, which may result in loss of control and serious injury or death. Slow down and use extra caution when operating on slippery surfaces.
  • Page 21 SAFETY Operator Safety Drive Belt Do not operate the engine with the drive belt removed. Any servicing that requires operation without a belt must be performed by your dealer. Operation of the engine with the belt removed may result in injury or damage to the engine. Intake Silencer Do not operate the engine with the intake silencer or filter removed.
  • Page 22 SAFETY Operator Safety Inadequate Snow Conditions WARNING Do not drive for prolonged periods on blacktop, gravel, or ice. Doing so could cause irreversible track damage and lead to serious injury. 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.
  • Page 23 SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently, and even the most docile condi- tions may become dangerous if operators drive improperly. If you’re new to snowmobiling, acquaint yourself with the machine and with what it will and won’t do under various conditions. Even seasoned driv- ers should spend some time getting the feel for a machine before attempting ambitious maneuvers.
  • Page 24 SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when tem- peratures become dangerous for riding. WIND CHILL CHART (°F) Wind Actual Thermometer Reading (_F) Speed -10 -15 -20 -25 -30 -35 -40 -45 Equivalent Temperature (_F) Calm -10 -15 -20 -25 -30 -35 -40 -45 -11 -16 -22 -28 -34 -40 -46 -52 -57 -63...
  • Page 25 If any decal becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety decals are provided by Polaris at no charge.
  • Page 26 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.
  • Page 27 Flashing light on dash indicates reverse operation. • Push button again to return to forward. Operation Warning The operation warning decal is located on the console of all Polaris snowmobiles. WARNING • To avoid serious injury or death, read and understand all warnings and the Owner’s Manual before operation.
  • Page 28 SAFETY Safety Decals and Locations Operation Warning (continued from previous page) • 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. •...

  • Page 29: Features

    FEATURES 1. Front Bumper (do not use for 9. Rear Bumper pulling or dragging the snow- 10. Snow Flap mobile) 11. Track 2. Hood 12. Suspension 3. Headlight 13. Tunnel 4. Windshield 14. Side Panel 5. Mountain Bar (if equipped) 15.
  • Page 30 FEATURES 1. Fuel Filler Cap 9. Parking Brake 2. Ignition Switch 10. Handlebar Grip Warmer Switch 3. MFD (Multi-Function Display) 11. Thumbwarmer Switch 4. Engine Stop Switch 12. Electronic Reverse Button 5. Throttle Control 13. MFD Control 6. Recoil Starter Handle 14.
  • Page 31 FEATURES Adjustable Headlights Move the adjuster to the left to lower the headlight beam. Move the adjuster to the right to raise the headlight beam. Adjustable Steering Adjuster The adjustable steering system allows you to adjust the handlebar position to fit your style of riding. See page 47.
  • Page 32 DET Troubleshooting (Carbureted Models) Use this chart to determine causes and solutions for detonation. If none of these conditions exists and the sensor remains activated, see your Polaris dealer for diagnosis. Possible Cause Solution Poor quality fuel Replace with higher quality fuel...
  • Page 33 FEATURES Instrumentation MFD Component Identification Item 1 Analog Gauge (if equipped) 2 Digital Gauge 3 Check Engine Indicator 4 Low Oil Indicator 5 High Temp Indicator 6 Brake Indicator 7 Reverse Indicator 8 High Beam Indicator...
  • Page 34 FEATURES Instrumentation Digital Display Identification Item 1 RPM or Speed Altitude (if equipped) Service Interval 2 Electrical System Voltage Level 3 MAX - Maximum MPH/ KPH or RPM MPH -Miles per hour KPH - Kilometers per hour RPM -Engine crankshaft revolutions per minute 4 Air Temp (if equipped)
  • Page 35 FEATURES Instrumentation MFD Settings The MFD Control Switch MODE allows you to set the MFD display to your preferences. The rocker switch has a MODE button (top) and a SET button (bottom). Specific instructions are outlined on the following pages. MFD Control Switch Standard vs.
  • Page 36 FEATURES Instrumentation MFD Digital Display Programs Press and release the MODE button to cycle through the three MFD pro- grams: Performance, Engine and History. Each program remains active until you cycle to the next program. While any program is active, press and release the SET button to cycle through the program’s screens.
  • Page 37 FEATURES Instrumentation MFD Digital Display Programs Performance Program Trip Settings Trip F automatically displays when the fuel level is low if the snowmobile is equipped with an electronic fuel gauge. The fuel symbol and the last fuel bar on the MFD gauge (if equipped) will blink when the fuel level reaches 1/8 of a tank.
  • Page 38 FEATURES Instrumentation MFD Digital Display Programs Engine Program Air Temperature (accessory) The MFD displays actual air temperature. Press and hold the MODE switch for ten sec- onds to switch between standard and metric units of measurement. Altimeter (accessory) The rider can calibrate the altimeter for cur- rent atmospheric conditions.
  • Page 39 FEATURES Instrumentation MFD Digital Display Programs History Program Press and release the MODE button until the history program screen is active. This screen will always display electrical system voltage level and fuel level (if equipped). Press and release the SET button to cycle through the following screens: maximum vehicle speed, maximum engine RPM and service interval reminder.
  • Page 40 FEATURES Instrumentation MFD Digital Display Programs History Program Service Interval Reminder The gauge logs the number of engine hours accumulated between service reminders. When the logged hours reaches the desig- nated service interval (set by the user), the gauge provides a reminder that service is due.
  • Page 41 FEATURES Instrumentation Gauge Cleaning 1. Wipe the gauge face as needed using a clean cloth and a mild soap and water solution. Wipe dry with clean, soft cloth. 2. Clean the back side of the gauge using a clean cloth and a mild soap and water solution.

  • Page 42: The Perfect Fit

    THE PERFECT FIT IQ Front Suspension Adjustments Independent Front Suspension (IFS) Break in the suspension for approximately 150 miles (240 km) before making any fine-tuning adjustments. Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions. We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference.
  • Page 43 THE PERFECT FIT IQ Front Suspension Adjustments Walker Evans Air Shocks Walker Evans Air shocks are oil filled shocks that use nitrogen pressure for spring force.These shocks are tuned for high performance riding in a wide range of winter riding conditions.You will notice slight differ- ences in ride height and spring rate at high and low temperature extremes.
  • Page 44 Front Shock Springs (Standard only) The front springs can be changed if spring preload alone isn't sufficient and further adjustment is desired to control suspension stiffness. See your Polaris dealer for more information.
  • Page 45 THE PERFECT FIT Rear Suspension Adjustments Rider weight, riding style, trail conditions, and vehicle speed all affect suspension action. Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. However, all sus- pension designs and adjustments involve a compromise, or trade-off.
  • Page 46 THE PERFECT FIT Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) To set up the rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement X. Take this measurement with no rider and with the rear suspension at full extension.
  • Page 47 THE PERFECT FIT Rear Suspension Adjustments Torsion Spring Preload To adjust rear torsion spring preload, rotate the three-position cam using the engine spark plug tool. Different rate torsion springs are available if a firmer ride is desired. Contact your dealer for more information. The following information is provided only as a guideline to be used for initial suspension set-up.
  • Page 48 THE PERFECT FIT Rear Suspension Adjustments Shock Compression Valving RMK Standard Rear Track Shock The standard RMK rear track shock is an Arvin MPV Select shock that allows for adjustments to the compression valving. Adjustments are made by turning the adjustment screw located near the base of the shock.
  • Page 49 THE PERFECT FIT Handlebar Adjustments WARNING Some aftermarket accessories (including windshields and cargo bags) may interfere with the handlebar. Such accessories could limit your ability to steer the vehicle and/or may contact the brake lever. This could lead to loss of con- trol resulting in serious injury or death.
  • Page 50 THE PERFECT FIT Handlebar Adjustments Handlebar Position 1. Loosen the four bolts on the Loosen top bolts to adjust bottom of the adjuster block. handlebar angle NOTE: If necessary, pry the blocks apart with a screwdriver. 2. Adjust the handlebar forward or rearward to the desired position.
  • Page 51 THE PERFECT FIT Accessories Polaris offers a wide range of accessories for your snowmobile to help make each ride more enjoyable. Use only Polaris parts and accessories on your Polaris snowmobile. Use of unapproved parts and accessories may result in: •...

  • Page 52: Pre-Ride Inspections

    PRE-RIDE INSPECTIONS Pre-Ride Checklist Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined on the refer- enced pages. Look for a checkmark (n) on the referenced pages to locate the pre-ride inspection items. Item See Page Drive Belt Condition...
  • Page 53 PRE-RIDE INSPECTIONS Before Starting the Engine Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start the engine without checking all vehicle components to be sure of proper operation. WARNING Operating the vehicle with worn, damaged, or malfunctioning components could result in serious injury or death.
  • Page 54 Inspect the recoil rope and handle for excessive wear, and make sure the knot securing the rope inside the handle is secure. If excessive wear is found, see your Polaris dealer for replacement. n Brakes Always check the following items for proper operation before starting the engine.
  • Page 55 PRE-RIDE INSPECTIONS Before Starting the Engine n Parking Brake Lever Lock Use the parking brake lever lock only when you want the snowmobile to remain stationary; for example, when parked on an incline for a period of five minutes or less. 1.
  • Page 56 The 2.4" powder track is designed specifically for deep snow applica- tions. Operation in low snow conditions at high speeds may cause track lug separation. Track lug separation is not covered under the Polaris limited warranty policy. Polaris does not recommend operation above 70 mph with this track.
  • Page 57 PRE-RIDE INSPECTIONS Before Starting the Engine n Suspension Inspection Loose nuts and bolts can reduce your snowmobile's reliability and cause needless repairs and 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.
  • Page 58 PRE-RIDE INSPECTIONS Start the Engine and Check Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never engage the starter when the engine is running. Never start the engine without checking all vehicle components to be sure of proper operation. See Before Starting the Engine beginning on page 50.

  • Page 59: Operation

    OPERATION Starting the Engine CAUTION 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 when the engine is running. 1. Turn the key to the ON position. Pull the engine stop switch up to the RUN position.
  • Page 60 Premix the first tank of gasoline with one pint of Polaris injection oil for each five gallons of fuel. This, in addition to the lubrication supplied by the injec- tion system, will assure proper engine break-in.
  • Page 61 This snowmobile is equipped with a variable exhaust system (VES). Engine lubrication comes from oil added to the fuel and oil injection systems. Polaris recommends the use of VES II 2 Cycle Oil for this engine. See page 112 for the part numbers of Polaris products.
  • Page 62 OPERATION Track Warm-Up WARNING A loose track or flying debris could cause serious injury or death. Stand clear of the front of the machine and the moving track. Never hold the snowmobile up or stand behind it while warming up the track. Do not use excessive throt- tle during warm-up or when the track is free-hanging.
  • Page 63 OPERATION Fuel Safety WARNING Gasoline is highly flammable and explosive under certain conditions. • Always exercise extreme caution whenever handling gasoline. • Always refuel outdoors or in a well-ventilated area. • Always turn off the engine before refueling. • Do not overfill the tank. Do not fill the tank neck. •...
  • Page 64 OPERATION Fuel For peak performance, Polaris recommends the use of 91 octane or higher fuel. Although 87 octane fuel is usable, some engine perfor- mance will be lost and fuel economy will decrease. Do not use lower than 87 octane fuel. Do not use fuel containing more than 10% ethanol (including E85).
  • Page 65 Never operate the engine if oil is not vis- ible in the tank. NOTE: The Polaris oil cap on the oil bottle is vented to allow proper oil flow. See your Polaris dealer for recommended replacement parts.
  • Page 66 OPERATION Engine Stop Switch Push down on the engine stop Stop switch to ground out the ignition Switch and stop the engine quickly. Pull the switch up to the RUN position to allow restarting. Throttle Safety Switch The throttle safety switch is designed to stop the engine whenever all pressure is removed from the throttle lever and the throttle cable or valves do not return to the normal closed position.
  • Page 67 When these switches are disconnected, the ignition key switch must be used to shut off the engine. DO NOT continue to operate the snowmobile with the throttle safety switch disconnected. Return the snowmobile to an authorized Polaris dealer for service as soon as possi- ble.
  • Page 68 OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 63 for more information about the engine stop switch. THROTTLE SYSTEM WHAT IT DOES CONDITION Ignition Switch Interrupts ignition circuit Brake Slows jackshaft Engine Stop Switch...
  • Page 69 OPERATION Electronic Reverse (PERCt) Electronic reverse will activate only if the engine RPM is below 4000. The maximum engine RPM will be 6000 when in reverse. WARNING Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Damage will occur to the chaincase or transmission if shifting is attempted when the engine is operating above idle speed.
  • Page 70 OPERATION Electronic Reverse (PERCt) Engaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Make sure the area behind your snow- mobile is clear. 3. Push the yellow reverse button on the left-hand control for one second, then release.
  • Page 71 OPERATION Daily Storage At the end of each ride, park the snowmobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4" (10 cm) off the ground. Remove the key and cover the snowmobile. Towing Do not use the front bumper to pull or drag the snowmobile.

  • Page 72: Maintenance

    MAINTENANCE Emission Control Information Any qualified repair shop or qualified person may maintain, replace, or repair the emission control devices or systems on your snowmobile. Emission Control Label Your snowmobile is equipped at the time of sale with an emission con- trol information (ECI) label and a factory-installed emissions informa- tion hangtag.
  • Page 73 The speci- fied maintenance for the fuel filter is recommended additional emission- related maintenance. Polaris recommends that you contact an authorized Polaris dealer to perform any service that may be necessary.
  • Page 74 Personal safety is critical when attempting to service or make adjust- ments to your snowmobile. If you're not familiar with safe service or adjustment procedures and the use of tools, or if you don't feel comfort- able performing these tasks yourself, contact an authorized Polaris dealer for service. CAUTION Hot components can cause damage to plastic.

  • Page 75: Item See Page

    The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. When inspection reveals the need for replacement parts, always use genuine Polaris parts, available from your Polaris dealer. Item Frequency Page 150 mi.

  • Page 76: Throttle Lever

    MAINTENANCE Periodic Maintenance Interval Table Item Frequency Page 150 mi. 500 mi. 1000 mi. 2000 mi. Pre- (240 km) (800 km) (1600 km) (3200 km) Season BRAKES Hose Routing Hose Condition Fluid Leaks Brake Pads Brake Disc Parking Brake Brake System 51, 91 Brake Fluid FUEL MANAGEMENT...

  • Page 77: Throttle Safety Switch

    MAINTENANCE Periodic Maintenance Interval Table Item Frequency Page 150 mi. 500 mi. 1000 mi. 2000 mi. Pre- (240 km) (800 km) (1600 km) (3200 km) Season ELECTRICAL Engine Stop Switch Throttle Safety Switch Ignition Switch Taillight Brakelight Headlight CHASSIS Ski Toe Alignment Suspension Mounting Bolts Steering Fasteners...
  • Page 78 The front suspension does not require lubrication. Rear Suspension Lubricate the suspension pivot shafts with Polaris Premium All Season Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 72 and before seasonal storage. When operating in heavy, wet snow conditions, lubricate every 500 miles (800 km).
  • Page 79 MAINTENANCE Lubrication Driveshaft Bearing Fitting Inject grease into the fitting on the speed- ometer 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. Throttle Cable Lubricate the throttle cable lightly with grease or oil.
  • Page 80 500 miles (800 km), then every 1000 miles (1600 km) or seasonally. Polaris recommends the use of Polaris Synthetic Chaincase Lube. See page 112 for the part numbers of Polaris products. Oil Check Sight Glass 1. Position the vehicle on a level sur- face.
  • Page 81 MAINTENANCE Lubrication Chaincase Oil Oil Change 1. Position the vehicle on a level surface. 2. Remove the drain plug and drain the oil into a drain pan. Allow the oil to drain completely. 3. Clean off all metal shavings from the plug.
  • Page 82 MAINTENANCE Spark Plugs Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color. WARNING A hot exhaust system and engine can cause serious burns.
  • Page 83 MAINTENANCE Spark Plugs A new engine can cause temporary spark plug fouling due to the preser- vative added during the assembly process. Avoid prolonged idle speeds, which cause plug fouling and carbonization. Change the spark plugs every 2000-2500 miles (3200-4000 km). CAUTION Using non-recommended spark plugs can result in serious engine damage.
  • Page 84 MAINTENANCE Intake Filters The intake foam filter limits Intake Foam Filters/Pre-filter snow ingestion into the intake system. When operating in loose powder snow, check the top of the foam filter periodically to remove any accumulation of snow. CAUTION Operating the snowmobile with the intake filters removed may cause intake icing.
  • Page 85 All fuel pump service must be performed by an authorized Polaris dealer. Do not attempt to service the fuel pump. Fuel Filter See your Polaris dealer for replacement of the fuel filter at the intervals outlined in the Periodic Maintenance Table beginning on page 72. Fuel Lines Inspect the fuel lines regularly for signs of deterioration or damage.
  • Page 86 CAUTION Operating the snowmobile with incorrect jetting can result in serious 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 balanced is important.
  • Page 87 Carburetor (Carbureted Models) Carburetor Water/Sediment Trap Most Polaris snowmobiles contain patented carburetor bowl water/sedi- ment traps located at the bottom of each carburetor. The trap, consisting of a hose with a plug, should be drained about every 1000 miles (1600 km) and inspected for contamination.
  • Page 88 MAINTENANCE Exhaust System Check the exhaust system for wear or damage at the intervals outlined in the Periodic Maintenance Table beginning on page 71. WARNING Hot exhaust system parts can cause serious burns. Allow adequate time for the exhaust system to cool. Never perform this procedure with the engine running.

  • Page 89: Coolant Level

    Contact your dealer if greater protection is required. Use Premium 60/40 anti-freeze coolant, which is already premixed and ready to use. Do not dilute with water. Never exceed a 60% antifreeze/ 40% water mixture. See page 112 for the part numbers of Polaris prod- ucts. NOTE: Never add tap water to the cooling system.
  • Page 90 This service must be performed when the engine is cold. Ask your Polaris dealer to check the coolant when he performs the fall tune-up on your snowmobile.
  • Page 91 MAINTENANCE Cooling System Bleeding the Cooling System WARNING Steam and hot liquids will cause serious burns to your skin. Never bleed the cooling system or remove the pressure cap when the engine is warm or hot. Use of a non-standard pressure cap will not allow the recovery system to function properly.
  • Page 92 MAINTENANCE Cooling System Bleeding the Cooling System Bleed the cooling system at the intervals outlined in the Periodic Main- tenance Table beginning on page 72. Perform the bleeding procedure when the engine is cold. 1. Remove the pressure cap and fill the coolant bottle with properly mixed coolant to the maximum mark.
  • Page 93 MAINTENANCE Drive Chain Tension Check drive chain tension weekly and before each long trip. To obtain correct chain tension: 1. Rotate the driven clutch Adjuster Bolt counterclockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly.
  • Page 94 MAINTENANCE Brakes n Hydraulic Brake Inspection Inspect the brake lever travel before each use of the snowmobile. See page 51. Brake pads must be replaced when the brake pad material becomes thin- ner than the backing plate, approximately 1/16" (1.5mm). A kit is avail- able for replacing brake pads.
  • Page 95 Replace when thickness is Brake Pad less than 1/16" (1.5mm). Material Excessive Lever Travel Hydraulic brakes are self- adjusting, but if excessive brake pad clearance develops (see page 91) bring the snow- mobile to an authorized Polaris dealer for inspection and adjustment.
  • Page 96 Brake fluid will damage decals, paint and some plastics. Always wipe up spills immediately. Sight Glass Replace brake fluid at least every two years with Polaris DOT 4 high tem- perature brake fluid. See page 112 for the part numbers of Polaris products. The brake fluid level can be seen through a plastic sight glass in the brake reservoir.
  • Page 97 MAINTENANCE Brakes Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action. Bleed the system before operating the snowmobile. WARNING Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an accident and lead to serious injury or death.
  • Page 98 MAINTENANCE Lights Removing Halogen Bulbs NOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fin- gers do touch the bulb, clean it with an alcohol-moistened towel. 1.
  • Page 99 Polaris dealer. Any unauthorized modifications to clutches, such as adding or removing weights, will void the warranty. CAUTION The bushings in the weights and rollers of Polaris clutches are made of a material that may be damaged if lubricated. Do not lubricate clutch bushings. Clutch Alignment Offset Clutch alignment offset is important for maintaining optimum perfor- mance.
  • Page 100 Drive Belt Condition Belt width and length must match the center distance of the clutches and sheave width of the drive clutch. For this reason, Polaris recommends that only O.E.M. belts be used. Other belts may match the dimensions, but can drastically change the shift pattern, resulting in poor perfor- mance.
  • Page 101 MAINTENANCE Clutch System Drive Belt Removal CAUTION Do not attempt to remove the drive belt after operating in reverse. The snow- mobile must be stopped after forward motion to prevent damage to compo- nents during belt removal. 1. Stop the engine after operating in a forward motion. NOTE: For easier accessibility, make sure the clutch tool access hole is visible between the 11:00 and 2:00 positions of the clutch sheave.
  • Page 102 MAINTENANCE Clutch System n Drive Belt Deflection Straight Edge Measure Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge on the belt and apply downward pressure while measuring at point A. This measurement should be 1 1/4"...
  • Page 103 MAINTENANCE Track Replacement When replacing the track, always install a track having the lug size rec- ommended for your model. See your Polaris dealer. CAUTION Installing tracks with larger lugs on machines equipped with coolers will result in damage to the cooler or tunnel. Always install a track having the lug size recommended for your model.
  • Page 104 MAINTENANCE Track Lubrication 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 operating for extended periods on ice and other surfaces that have lit- tle or no snow for lubrication.
  • Page 105 MAINTENANCE Track Tension WARNING Moving parts can cut and crush body parts. When performing the checks and adjustments recommended on the following pages, stay clear of all moving parts. Never perform track measurement or adjustments with the engine run- ning. Track tension is critical for maximum efficiency and performance.
  • Page 106 MAINTENANCE Track Tension Adjusting Idler Shaft Bolt Screw Lock 10 lbs. (4.54 kg) 16" (40 cm) If the track needs adjustment: 5. Loosen the rear idler shaft bolt. 6. Loosen the lock nuts. 7. Tighten or loosen the track adjusting screws as necessary to provide equal adjustment on both sides of the track.

  • Page 107: Track Alignment/Condition

    MAINTENANCE Track Alignment Periodically check that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. 1. Safely support the rear of the snowmobile with the track off the ground.
  • Page 108 MAINTENANCE Steering System Steering Inspection and Adjustment Check all steering system fasteners weekly and before a long ride. Tighten any loose fasteners.
  • Page 109 Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski align- ment or camber adjustment. See your Polaris 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.
  • Page 110 MAINTENANCE Steering System n Ski Skags WARNING Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causing serious injury or death. See your dealer's studding chart for recommended skags. If you install longer or more aggressive carbide skags than the original equipment, it may also be necessary to add track studs to maintain proper vehicle control while turning on hard-packed snow or ice.
  • Page 111 MAINTENANCE Steering System n Rail Slide Wear For ease of inspection, all Polaris rail slides have a Minimum wear limit indicator groove Thickness to indicate the minimum permissible slide thick- ness. Replace the rail slides if they are worn to the top of the groove at any point along their length.
  • Page 112 Extended Storage Off-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components. See page 112 for the part numbers of Polaris prod- ucts. Cleaning and Preservation Proper storage starts with cleaning, washing, and waxing the hood, chassis, and plastic parts.
  • Page 113 MAINTENANCE Extended Storage Engine and Carburetor Protection (Carbureted Models) Proper preparation of the engine and fuel system is vital to the preven- tion of rust 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.
  • Page 114 MAINTENANCE Extended Storage Electrical Connections Replace worn or frayed electrical wire and connectors. Be sure wiring harness is properly secured away from sharp edges, steering linkage, moving parts, and hot exhaust parts. Track and Suspension Moderate track tension should be maintained during summer storage. The machine should be supported off the ground to allow the track to hang freely.

  • Page 115: Polaris Products

    POLARIS PRODUCTS Part No. Description Engine Lubricants 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2-Cycle Engine Oil (qt.) 2871097 Premium 2-Cycle Engine Oil (gal.) 2871240 Premium 2-Cycle Engine Oil (2.5 gal.) 2871721 Premium Gold Synthetic 2-Cycle Engine Oil (qt.) 2871722 Premium Gold Synthetic 2-Cycle Engine Oil (gal.)

  • Page 116: Troubleshooting

    TROUBLESHOOTING Engine Troubleshooting Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Probable Cause Solution Erratic engine oper- Drive clutch binding • SEE YOUR DEALER. ating RPM during Driven clutch mal- •...
  • Page 117 TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Noise in drive sys- Broken drive clutch • SEE YOUR DEALER. components Bearing failure/ • SEE YOUR DEALER. chaincase, jackshaft, or front drive shaft Drive belt surface • Inspect and replace as needed. flat spots Drive chain loose •...
  • Page 118 TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Engine turns but fails Faulty ignition • Install new spark plug(s). If engine to start still fails to start, check for spark. If there's no spark, SEE YOUR DEALER. No fuel to engine •...
  • Page 119 TROUBLESHOOTING Suspension Troubleshooting Problem Solution Rear suspension bot- • Set static sag (see page 43). Adjust torsion spring blocks or toms too easily install optional torsion springs to achieve correct sag dimensions. Rides too stiff in rear • Check for binding suspension components and grease all pivot points.
  • Page 120 TROUBLESHOOTING Drive Belt Troubleshooting Belt Wear/Burn Diagnosis Causes Solutions Driving at low RPM • Drive at higher RPM. Gear the machine down. Check belt deflection. Insufficient warm-up • Warm the engine at least five minutes. Take the drive belt off the machine in extremely cold weather and warm it up.

  • Page 121: Warranty

    Your dealer is also familiar with Polaris policies and procedures and will be happy to assist you. When contacting us about parts, service, or warranty, always provide the following information: 1.
  • Page 122 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 notifying the proper owner when a unit is recovered...
  • Page 123 WARRANTY Limited Warranty Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM- ITED WARRANTY on all components of the Polaris snowmobile against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective parts that are covered by this warranty.
  • Page 124 How to Obtain Warranty Service If your snowmobile requires warranty service, you must take it to a Polaris dealer autho- rized to repair Polaris snowmobiles. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (The cost of transportation to and from the dealer is YOUR responsibility).
  • Page 125 In order to qualify for warranty, the product must have been properly set up and tested by a Polaris Dealer (if applicable). Failure of any dealer to perform the required vehicle Pre-Delivery Inspection, perform all applicable service bulletins and have the consumer sign the PDI form prior to delivery may void the warranty.
  • Page 126 • Failures caused due to improper adjustments. • Failure due to unauthorized service. • Failures due to lack of service as required in the owner’s manual or Polaris updates. This includes off-season storage as listed in the owner’s manual. • Failure due to use of unauthorized parts or modifications.
  • Page 127 If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied.
  • Page 128 Protection Agency regulations applicable to snowmobile emissions under 40 CFR1051, 1065 and 1068 at the time of sale to the ultimate purchaser. Polaris warrants that the engine is free from defects in materials and workmanship that may keep it from meeting these regulations.
  • Page 129 Any qualified repair shop or qualified person may maintain, replace, or repair the emission control devices or systems on your snowmobile. Polaris recom- mends that you contact an authorized Polaris dealer to perform any service that may be necessary.

  • Page 130: Maintenance Log

    MAINTENANCE LOG Present this section of your manual to your dealer 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 TECHNICIAN SERVICE PERFORMED / COMMENTS (KM) 150 mi.
  • Page 131 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)
  • Page 132 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)

  • Page 133: Index

    INDEX Accessories ....48 Drive Belt ..... 18 Apparel for Riding.
  • Page 134 Intake Silencer ....18 Polaris Products ....112 Pre-Ride Checklist ... 49-55 Pressure Cap Warning .
  • Page 135 INDEX Snow Build-up ....16 Tether Switch....48 Snow Conditions .

This manual is also suitable for:

600 rmk700 rmk700 dragon rmk800 dragon rmk

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