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Polaris 600 RMK 144 Owner's Manual

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PMS 419
600 RMK 144
600 RMK 144 ES
600 RMK 155
600 RMK 155 ES
Snowmobile Owner's Manual
for Maintenance and Safety

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Summary of Contents for Polaris 600 RMK 144

  • Page 1 PMS 419 600 RMK 144 600 RMK 144 ES 600 RMK 155 600 RMK 155 ES Snowmobile Owner's Manual for Maintenance and Safety...
  • Page 2 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 3 The text is printed on 100% recycled with 40% post-consumer waste (PCW).
  • Page 4 PMS 419 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. 9922868 Rev 01 Printed in USA *9922868...
  • Page 5 ® • Low emission vehicles (LEVs) 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 6 POLARIS, THE WAY OUT, PERC, IQ and RMK are registered trademarks of Polaris Industries Inc. Copyright 2010 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 7: Table Of Contents

    Polaris Products ......104 Troubleshooting ......105 Warranty .

  • Page 9: 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 10 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 11: Vehicle Identification Numbers

    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 12: 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 indicates a potential personal injury hazard. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.
  • Page 13 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 opera- tion with any modifications, especially those that increase speed or power. DO NOT MODIFY YOUR MACHINE.
  • Page 14 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 15: Survival Preparation

    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 16: Eye Protection

    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 17: Disabled Operators

    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 18: Driver Awareness

    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 19 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 20: Ice And Snow Build-Up

    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 21: Driving On Slippery Surfaces

    SAFETY Operator Safety Driving on Slippery Surfaces WARNING! Never attempt an abrupt change of direction when operating on slippery surfaces. 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.

  • Page 22: Drive Belt

    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. NOTICE: Operation of the engine with the belt removed may result in injury or damage to the engine.

  • Page 23: Operating In Deep Snow

    SAFETY Operator Safety 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.

  • Page 24: Driving Responsibly

    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 25 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 26: Clutch Cover Warning

    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 27: Track Warning

    Do Not Touch Burns may result. Entire top of tun- nel may be hot. Install only accesso- ries specifically approved for this model by Polaris. Do not place cloth- ing, bags or cargo on tunnel. Do not cover this label.

  • Page 28: Reverse Warning

    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 29 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 30: Features

    FEATURES Front Bumper (do not use for Rear Bumper pulling or dragging the snowmo- 10. Snow Flap bile) 11. Track Hood 12. Suspension Headlight 13. Tunnel Windshield 14. Side Panel Mountain Bar (if equipped) 15. Ski Handlebar 16. Nosepan Seat Taillights...
  • Page 31 FEATURES Fuel Filler Cap Parking Brake Ignition Switch 10. Handlebar Grip Warmer Switch MFD (Multi-Function Display) 11. Thumbwarmer Switch Engine Stop Switch 12. Electronic Reverse Button Throttle Control 13. MFD Control Recoil Starter Handle 14. Headlight Dimmer Switch Hood Hold-Down Straps Brake Lever...
  • Page 32 FEATURES Adjustable Headlights Move the adjuster to the left to lower the headlight beam. Move the adjuster to the right to Adjuster raise the headlight beam. Headlight Dimmer Switch Use the headlight dimmer switch to adjust the headlights between high beam and low beam. Switch headlights to low beam when meeting oncoming traffic.
  • Page 33 FEATURES Detonation Elimination Technology (DET) A detonation sensor monitors the engine and responds to detonation by automatically reducing the engine timing and adding fuel. This results in decreased engine RPM and performance. Effect of DET The DET system prevents damage to the engine from detonation while developing the maximum power of the engine safely.
  • Page 34 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 35 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 36: Mfd Settings

    FEATURES Instrumentation MFD Settings The MFD Control Switch allows MODE you to set the MFD display to your preferences. The rocker switch has a MODE button (top) and a SET button (bottom). Specific instruc- tions are outlined on the following pages.
  • Page 37 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 38 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 39 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 40 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 41 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 42: Gauge Cleaning

    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 43: 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 44 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. Shock Absorber Components 1. Retainer 2.

  • Page 45: Suspension Performance Tips

    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: Torsion Spring Preload

    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: Shock Compression Valving

    THE PERFECT FIT Rear Suspension Adjustments Shock Compression Valving 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: Handlebar Adjustments

    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 control resulting in serious injury or death.
  • Page 50 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 51: 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.

  • Page 52: Before Starting The Engine

    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 53 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 54: Parking Brake Lever Lock

    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 station- ary; for example, when parked on an incline for a period of five minutes or less. 1.

  • Page 55: Steering System

    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 56: Suspension Inspection

    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 57 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 48.

  • Page 58: Operation

    OPERATION Starting the Engine 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 when the engine is running. 1. Turn the key to the ON position. Pull the engine stop switch up to the RUN position.

  • Page 59: 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 separate fuel container.
  • Page 60 NOTICE: Use of any lubricants other than those recommended by POLARIS may cause serious engine damage. We recommend the use of POLARIS lubricants for your vehicle.

  • Page 61: Slide Rail And Track Cooling

    OPERATION Slide Rail and Track Cooling NOTICE: Inadequate cooling and lubrication will lead to overheating of the slide rail and track, resulting in premature wear and failure. Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces.

  • Page 62: Fuel Safety

    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 63: Fuel System Deicers

    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 64: Low Oil Indicator Light

    Always do a visual check of the oil level when refueling. When the oil reaches the low level mark, add the recommended oil to the tank. The POLARIS oil cap on the oil bottle is vented to allow proper oil flow. See your POLARIS dealer for recommended replacement parts.
  • Page 65 OPERATION Engine Stop Switch Push down on the engine stop Stop switch to ground out the igni- Switch tion 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 66: Throttle Lever

    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 67: Throttle Safety Switch

    OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 61 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 68 OPERATION Electronic Reverse (PERC) 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 trans- mission if shifting is attempted when the engine is operating above idle speed. •...
  • Page 69 OPERATION Electronic Reverse (PERC) Engaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Make sure the area behind your snowmobile is clear. 3. Push the reverse button on the left- hand control for one second, then release. The engine will automatically reduce RPM and start a reverse Reverse Button rotation.
  • Page 70 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 71: Maintenance

    Please read the Snowmobile Engine Emissions Limited Warranty, and read the maintenance section of your owner's manual. You are responsi- ble for ensuring that the specified maintenance is performed. Polaris recommends that you contact an authorized Polaris dealer to perform any service that may be necessary.
  • Page 72 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. NOTICE: Hot components can cause damage to plastic. Always make sure the exhaust system and engine have cooled before tipping the snowmo- bile on its side for service or inspection.
  • Page 73 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 74: Taillight/Brakelight/Headlight

    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 49, 84 Brake Fluid FUEL MANAGEMENT...

  • Page 75: Suspension Mounting Bolts

    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 CHASSIS Ski Toe Alignment Suspension Mounting Bolts Steering Fasteners Rear Suspension Fasteners Cooling Fins/Shroud Drive Shaft Bearings Jackshaft Bearings Skags (Wear Bars)

  • Page 76: Front Suspension

    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 69 and before seasonal storage. When operating in heavy, wet snow conditions, lubricate every 500 miles (800 km).

  • Page 77: Throttle Cable

    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 78 500 miles (800 km), then every 1000 miles (1600 km) or seasonally. Polaris recommends the use of Polaris Synthetic Chaincase Lube. See page 104 for the part numbers of Polaris products. Oil Check Sight Glass 1. Position the vehicle on a level sur- face.
  • Page 79 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 80: Spark Plugs

    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. CAUTION! A hot exhaust system and engine can cause burns.
  • Page 81 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). NOTICE: Using non-recommended spark plugs can result in serious engine damage.

  • Page 82: Intake Filters

    Fuel Injectors All fuel injector service must be performed by an authorized Polaris dealer. Do not attempt to clean or service the fuel injectors. Fuel Pump All fuel pump service must be performed by an authorized Polaris...

  • Page 83: Fuel Filter

    MAINTENANCE Fuel Filter See your Polaris dealer for replacement of the fuel filter at the intervals outlined in the Periodic Maintenance Table beginning on page 69. Contaminated or poor quality fuel will shorten the life of the fuel filter and result in poor engine performance. Always store fuel in clean fuel containers.

  • Page 84: Cooling System

    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 104 for the part numbers of Polaris prod- ucts. TIP: Never add tap water to the cooling system. Minerals cause deposits and may react adversely with the metals in the engine and cooling system.
  • Page 85 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 86 MAINTENANCE Cooling System Bleeding the Cooling System Bleed the cooling system at the intervals outlined in the Periodic Main- tenance Table beginning on page 69. 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 87: Drive Chain Tension

    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 counterclockwise to move all Bolt chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly.

  • Page 88: Brake Components

    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 84) bring the snow- mobile to an authorized Polaris dealer for inspection and adjustment.

  • Page 89: Brake Fluid

    MAINTENANCE Brakes n Brake Fluid Replace brake fluid at least every two years with Polaris DOT 4 high temperature brake fluid. See page 104 for the part numbers of Polaris products. WARNING! After opening a bottle of brake fluid, always discard any unused portion.
  • Page 90 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 91 MAINTENANCE Lights Removing Halogen Bulbs 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 92 Polaris dealer. Any unauthorized modifications to clutches, such as add- ing 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 lubricate clutch bushings.

  • Page 93: Troubleshooting

    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 94 MAINTENANCE Clutch System Drive Belt Removal NOTICE: Do not attempt to remove the drive belt after operating in reverse. The snowmobile must be stopped after forward motion to prevent damage to components during belt removal. 1. Stop the engine after operating in a forward motion. TIP: 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 95: Drive Belt Installation

    MAINTENANCE Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. The belt cord line should be flush with, or slightly above, the outer circumference of the driven clutch sheaves. The belt will seat itself in the driven clutch during the break-in period.
  • Page 96 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 97: Track Replacement

    Track Replacement When replacing the track, always install a track having the lug size rec- ommended for your model. See your Polaris dealer. NOTICE: Installing tracks with larger lugs on machines equipped with coolers will result in damage to the cooler or tunnel. Always install a track hav- ing the lug size recommended for your model.
  • Page 98 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 running. Track tension is critical for maximum efficiency and performance. Track tension controls the approach angle of the track to the rail beam in powder snow conditions.
  • Page 99 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 100: 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 101 MAINTENANCE Steering System Steering Inspection and Adjustment Check all steering system fasteners weekly and before a long ride. Tighten any loose fasteners.

  • Page 102: Ski Alignment

    WARNING! Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski alignment 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 103 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 104: Rail Slide Wear

    MAINTENANCE Steering System n Rail Slide Wear For ease of inspection, all Polaris rail slides have a wear limit indicator groove Minimum to indicate the minimum Thickness 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 105 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 104 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 106: Engine Protection

    Lubricate all bushings, spindle shafts, tie rod ends and cables as outlined in the Periodic Maintenance Table beginning on page 69. Bearings Grease the jackshaft and drive shaft clutch side bearings with Polaris Premium All-Season Grease or a similar high quality grease to prevent corrosion.

  • Page 107: Electrical Connections

    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 108: Polaris Products

    POLARIS PRODUCTS Description Part No. Engine Lubricants 2870791 Fogging Oil (12 oz. Aerosol) 2875035 Premium 2-Cycle Semi-Synthetic Oil (qt./.95 l) 2875036 Premium 2-Cycle Semi-Synthetic Oil (gal./3.8 l) 2875038 Premium 2-Cycle Semi-Synthetic Oil (2.5 gal./9.5 l) 2877882 VES Gold Plus 2-Cycle Oil (qt./.95 l) 2877883 VES Gold Plus 2-Cycle Oil (gal./3.8 l)

  • Page 109: 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 110 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 111 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 112 TROUBLESHOOTING Suspension Troubleshooting Problem Solution Rear suspension bot- • Set static sag (see page 42). 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 113 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 114: 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 115 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 116: Limited Warranty

    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 117: Engine Oil

    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 118 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 119 How to Get Service In the Country where your vehicle was purchased: Warranty or Service Bulletin repairs must be done by an authorized Polaris dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized Polaris dealer who sells the same line as your vehicle.
  • Page 120 Exported Vehicles 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. You must nonetheless warranty register your vehicle under your name and address with a local POLARIS dealer in your country to ensure that you receive safety information and notices regarding your vehicle.
  • Page 121 This emissions limited warranty is in addition to the Polaris standard limited warranty for your vehicle. Polaris Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applica- ble U.S.
  • Page 122 Polaris dealer to perform any service that may be necessary for your vehicle. Polaris also recommends that you use only Pure Polaris parts. It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle's emission controls.

  • Page 123: 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 124 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)
  • Page 125 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)

  • Page 126: Index

    INDEX Accessories ....46 Drive Belt Apparel for Riding....12 Adjustment .

  • Page 127: Index

    Intake Silencer ....18 Polaris Products ....104 Pre-Ride Checklist ... 47-53 Pressure Cap Warning .
  • Page 128 INDEX Spark Plugs ....76-77 Tether Switch....46 Speed .

This manual is also suitable for:

600 rmk 155600 rmk 155 es

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