Polaris 2015 600 RMK Owner's Manual
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Polaris 2015 600 RMK Owner's Manual

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IMPORTANT NOTICE TO OWNER
Modifications to this snowmobile are not recommended
and may result in voided warranty coverage.
Please read the warranty section of this manual carefully.
600 RMK
600 PRO RMK
800 RMK
800 PRO RMK
800 RMK ASSAULT
Snowmobile Owner's Manual
for Maintenance and Safety

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Summary of Contents for Polaris 2015 600 RMK

  • Page 1 IMPORTANT NOTICE TO OWNER Modifications to this snowmobile are not recommended and may result in voided warranty coverage. Please read the warranty section of this manual carefully. 600 RMK 600 PRO RMK 800 RMK 800 PRO RMK 800 RMK ASSAULT 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 WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www.polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products.
  • Page 4 QUICKDRIVE® PERC® ASSAULT® Copyright 2014 Polaris Industries Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication.

  • Page 5: Table Of Contents

    Specifications ......117 POLARIS Products..... 121 Troubleshooting .

  • Page 7: Introduction

    INTRODUCTION Important Notes for Owners and Drivers After reading this manual, store it in the snowmobile for convenient reference. It should remain with the snowmobile when the snowmobile is sold. Some of the illustrations and photos used in this manual are general representations.

  • Page 8: Air Pollution

    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 9: Vehicle Identification Numbers

    Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a POLARIS key blank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced.

  • Page 10: 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 symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. DANGER A DANGER indicates a hazardous situation that, if not avoided, will result in death or serious injury.
  • Page 11 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 12: Riding Position

    SAFETY Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. Do not stand on the plastic flap. WARNING! Serious injuries may result if NO STEP hands, feet, or clothing become entangled in the track.

  • Page 13: Riding Apparel

    Riding Apparel Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.

  • Page 14: Disabled Operators

    SAFETY Operator Safety Disabled Operators Safe operation of this rider-active vehicle requires good judgement and physical skills. Operators with cognitive or physical disabilities have an increased risk of loss of control, which could result in serious injury or death. Survival Preparation For your safety, always ride in a group of other snowmobilers.

  • Page 15: Rider Capacity

    SAFETY Operator Safety Rider Capacity This snowmobile is designed for a single rider only. Never carry a passenger on this snowmobile. Excessive Speed WARNING! High speed driving, especially at night, could result in serious injury or death. Always reduce speed when driving at night or in inclement weather. Always observe all state and local laws governing snowmobile operation and speed limits.

  • Page 16: 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. Guy wires on utility poles are also difficult to distinguish.
  • Page 17 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 18: 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 19: Driving Downhill

    SAFETY Operator Safety Driving Downhill When riding downhill, shift your weight to the rear of the snowmobile and reduce your speed to a minimum. Apply just enough throttle to keep the clutch engaged, allowing the engine's compression to help slow the snowmobile and keep it from rolling freely downhill.

  • Page 20: 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 21: Driving Responsibly

    SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently, and even the most docile conditions may become dangerous if operators drive improperly. If you're new to snowmobiling, acquaint yourself with the snowmobile and with what it will and won't do under various conditions. Even seasoned drivers should spend some time getting the feel for a snowmobile before attempting ambitious maneuvers.
  • Page 22 SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding. WINDCHILL 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 23: Clutch Warning

    If any label becomes illegible or comes off, contact your POLARIS dealer to purchase a replacement. Replacement safety labels are provided by POLARIS at no charge. The part number is printed on the label. Clutch Warning...

  • Page 24: Reverse Warning

    SAFETY Safety Labels and Locations “No Passenger” Warning Reverse Warning “No Passenger” Warning Snowmobiles designed for a single rider only have the NO PASSENGER warning label on the lower left side of the console: WARNING This vehicle is designed for operator only. NO PASSENGER Reverse Warning The reverse warning label is located on the console, either beside the steering post or below the windshield:...

  • Page 25: Hot Surface Warning

    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 26 • To avoid serious injury or death, read and understand all warnings and the Owner's Manual before operation. If manual is missing, contact a POLARIS dealer for a replacement. • This vehicle is capable of high speeds. Buried objects or uneven terrain can cause loss of control.
  • Page 27 SAFETY Safety Labels and Locations Operation Warning • When operating with a passenger (on approved models only) reduce speed and allow extra space for steering and stopping. A passenger reduces your ability to control the vehicle. • When operating on hard-packed snow, ice, or when crossing roads, steering and braking ability are greatly reduced.

  • Page 28: Features

    FEATURES 1. Nosepan 8. Operator Seat 2. Skis 9. Taillight 3. Front Bumper 10. Rear Bumper 4. Hood 11. Snow Flap 5. Headlight 12. Suspension 6. Windshield (accessory) 13. Track 7. Handlebar 14. Side Panel 15. Side Panel Fasteners...
  • Page 29 FEATURES 1. Fuel Filler Cap 2. Instrument Cluster 3. Ignition Switch 4. Engine Stop Switch 5. Throttle Control 6. Recoil Starter Handle 7. Brake Lever 8. Parking Brake Lock 9. Handlebar Grip Warmer Switch 10. Thumbwarmer Switch 11. Electronic Reverse Button 12 13 12.

  • Page 30: Adjustable Headlights

    FEATURES Storage Bag/Tool Kit A storage bag and tool kit Storage Bag is located under the left side panel between the oil bottle and console. Cargo Storage Never hang heavy items or fuel containers from the rear of the tunnel. Cargo may be stowed only under the seat and as far forward as possible...

  • Page 31: Quickdrive Belt

    Maintenance Table beginning on page 80. See page 99 for inspection procedures. Special tools are required to remove and install the QUICKDRIVE belt. Please see your POLARIS dealer for this service, or refer to the instructions provided with the purchase of a new belt. Belt Handling •...
  • Page 32 FEATURES 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: • Non-compliance with government/industry requirements •...

  • Page 33: Fuel Type Selection

    FEATURES Fuel Type Selection Whenever using ethanol, MTBE or other forms of oxygenated gasoline, the fuel type designation setting must be changed to “Eth” in the gauge. When using the recommended 91 non-ethanol gasoline, always select the “91-non” setting. Whenever in doubt of your fuel purchase, use the “Eth”...
  • Page 34 FEATURES Detonation Elimination Technology (DET) The DET system prevents damage to the engine from detonation by going into an engine protection mode whenever the DET system is active. When excessive detonation is detected, the check engine light will illuminate and you may notice decreased engine performance and RPM when the DET system is activated.
  • Page 35 Low fuel/no fuel in tank Refuel with recommended fuel Water in fuel Replace with recommended fuel Plugged fuel filter or tank pick-up sock See your POLARIS dealer for service Alcohol-based fuel additive used with Do not add deicers or additives that Ethanol fuel...
  • Page 36 FEATURES Instrument Cluster Rider Information Center Check Engine High Beam Indicator Indicator Over-Tem- Park Brake perature Indi- Indicator cator Reverse Low Oil Indicator Indicator SELECT MODE Button Button The instrument cluster contains indicator lights and the rider information center. The information center can be controlled by either the MODE and SELECT buttons on the instrument cluster or by the...
  • Page 37 FEATURES Instrument Cluster Indicators Check Engine Indicator This indicator appears if an EFI-related fault occurs. Do not operate the snowmobile if this warning appears. Serious engine damage could result. See your dealer. See page 48 for diagnostic code definitions. Over-Temperature Indicator This indicator illuminates to alert the operator that the engine is overheating.
  • Page 38 FEATURES Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. The center displays vehicle speed, engine speed, odometer, resettable trip meters (2), total engine hours of operation, fuel level, engine temperature and diagnostic display mode. Setting changes must be made with the engine running or with the vehicle powered by an external DC power supply connector.
  • Page 39 FEATURES Instrument Cluster Rider Information Center 1. Information Display Area - This area displays either engine speed or vehicle speed (whichever is not displayed in the speed display), engine temperature and maximum vehicle speed. To change the display, see page 38. 2.
  • Page 40 FEATURES Instrument Cluster Rider Information Center Speed Display Area The speed display area displays either vehicle speed or engine speed. Vehicle speed is displayed in either miles per hour (MPH) or kilometers per hour (km/h). Engine speed is displayed in revolutions per minute (RPM).
  • Page 41 FEATURES Instrument Cluster Rider Information Center Odometer/Engine Hour Display Area This area displays the odometer, Trip A meter, Trip B meter and engine hours meter. The odometer displays the total distance traveled by the vehicle since manufacture. Each trip meter records the distance traveled by the vehicle on a trip if the meter is reset before each trip.
  • Page 42 FEATURES Instrument Cluster Rider Information Center Standard/Metric Display The odometer and temperature displays can be viewed in either standard or metric units of measurement. Both displays change if units are changed. The new settings will remain until changed by the operator. Change Method 1 1.
  • Page 43 Security System (Ignition Lock System) This system is an optional feature and will not function until it has been activated by your authorized POLARIS dealer. If you have this feature activated, you can lock the ignition to prevent unauthorized use when leaving the snowmobile unattended.
  • Page 44 TASK 1: Activate the security system See your authorized POLARIS dealer to have the optional security system feature activated in the electronic control unit (ECU). TASK 2: Lock the System the First Time 1.
  • Page 45 FEATURES Instrument Cluster Rider Information Center Security System (Ignition Lock System) First Time Use of Your Security System TASK 3: Unlock the System 1. When the engine is running, the display will alternate between SECURE ON and ENTER CODE. Wait until ENTER CODE displays, then press and release SEL to advance the digit.
  • Page 46 FEATURES Instrument Cluster Rider Information Center Security System (Ignition Lock System) Locking the System With Your Personal Security Code 1. Start the engine and lock the parking brake. 2. Press and hold the MODE and SEL buttons for 3 seconds, then release. SECURE OFF should be displayed.
  • Page 47 FEATURES Instrument Cluster Rider Information Center Security System (Ignition Lock System) Unlocking the System With Your Personal Security Code 1. When the engine is running, the display will alternate between SECURE ON and ENTER CODE. Wait until ENTER CODE displays, then press and release SEL to advance the digit.
  • Page 48 FEATURES Instrument Cluster Rider Information Center Security System (Ignition Lock System) Changing to a New Security Code Any time you wish to change your current security code to a new code, perform TASK 2 through TASK 4 of the First Time Use of Your Security System procedure beginning on page 42.

  • Page 49: Diagnostic Display Mode

    Diagnostic Display Mode The diagnostic display mode is for informational purposes only. Please see your POLARIS dealer for all major repairs. The diagnostic mode is accessible only when the check engine warning indicator is illuminated and a diagnostic code is active.
  • Page 50 FEATURES Instrument Cluster Rider Information Center Diagnostic Display Code Definitions Open Load: There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed. Short-to-Ground: The wire is shorted to ground between the electronic control unit and the item listed in the chart.

  • Page 51: Diagnostic Codes

    FEATURES Instrument Cluster Rider Information Center Diagnostic Display Code Definitions Diagnostic Codes Component Condition ECU Memory Checksum/CRC Error Injector 1 (MAG) (Port Injector) Driver Circuit Open/Grounded Driver Circuit Short to B+ Injector 2 (PTO) (Port Injector) Driver Circuit Open/Grounded Driver Circuit Short to B+ Knock Sensor 1 Voltage Too Low Ignition Coil Primary Driver 1 (MAG)

  • Page 52: The Perfect Fit

    THE PERFECT FIT Suspension Adjustments Factory settings, combined with user adjustments to the rear track shock spring (RTSS), should be all that’s necessary to provide the best riding experience for most riders. The primary adjustment for overall vehicle balance is RTSS preload. Perform this adjustment first. Always perform shock spring preload adjustments with the weight of the vehicle removed from the shock and with the shock at full extension.
  • Page 53 See page 50. TIP: If adjustments to the factory-installed springs are not sufficient for riders over 300 lbs. (136 kg), optional heavy springs are available. Please see your POLARIS dealer. Initial RTSS Preload Settings (Measure spring length with suspension off the ground)
  • Page 54 THE PERFECT FIT Suspension Adjustments Fine-Tuning Your Suspension Set-Up The primary adjustment for overall vehicle balance is RTSS preload. Adjust the factory-set preload to the recommended setting for your weight and then test ride. Additional minor adjustments can then be made to the spring preload to adjust the feel of the vehicle.
  • Page 55 THE PERFECT FIT Suspension Adjustments Shock Compression Damping (RMK/ASSAULT RMK) The primary adjustment for overall vehicle balance is RTSS preload. Perform this adjustment first. See page 50. After adjusting RTSS preload to your satisfaction, compression damping adjustments can be made to control ride quality and bottoming resistance. 800 RMK Damping Screw Make the adjustments in half-turn...
  • Page 56 THE PERFECT FIT Suspension Adjustments Independent Front Suspension and Front Track Shock Spring Preload (RMK/PRO-RMK) Factory settings, combined with user adjustments to the rear track shock spring, should be all that’s necessary to provide the best riding experience for most riders. The primary adjustment for overall vehicle balance is RTSS preload.

  • Page 57: Handlebar Adjustments

    THE PERFECT FIT Handlebar Adjustments Loosen top bolts to adjust handlebar angle Loosen bottom bolts to adjust handlebar position (if equipped) Handlebar Position (if equipped) 1. Loosen the four bolts on the bottom of the adjuster block. If necessary, pry the blocks apart with a screwdriver. 2.

  • Page 58: 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 referenced pages. Item See Page Drive Belt or QUICKDRIVE Belt Steering System Recoil Rope Coolant Level Chaincase Oil Level Injection Oil Level...

  • Page 59: Item See Page

    PRE-RIDE INSPECTIONS Pre-Ride 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 following items on a weekly basis or before any long trip. Item See Page Check suspension mounting bolts for tightness.

  • Page 60: Throttle Lever

    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 61 PRE-RIDE INSPECTIONS Before Starting the Engine Brakes Always check the following items for proper operation before starting the engine. Brake Lever Travel Squeeze the brake lever. It should move no closer to the 1/2 in. (1.3 cm) handgrip than 1/2 inch (1.3 cm).

  • Page 62: Parking Brake Lever Lock

    PRE-RIDE INSPECTIONS Before Starting the Engine 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 63: Steering System

    Recoil Rope 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.

  • Page 64: Ignition Switch

    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 58.

  • Page 65: 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. 2.
  • Page 66 OPERATION Starting the Engine Restarting an Engine If the rider stops the engine by pushing the engine stop switch down, restart the engine using the normal starting procedure. If the engine fails to start using the normal procedure: 1. Push the engine stop switch down to the OFF position. 2.
  • Page 67 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 68: Oil Injection System

    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 69 OPERATION Break-In Period Drive Belt/QUICKDRIVE Belt Break-In The length of the break-in period varies depending on the type of drive system. The break-in period for a new drive belt is 30 miles (48 km). The break-in period for a new QUICKDRIVE belt is 100 miles (160 km).

  • Page 70: Track Warm-Up

    OPERATION Track Warm-Up WARNING! A loose track or flying debris could cause serious injury or death. Stand clear of the front of the snowmobile and the moving track. Never hold the snowmobile up or stand behind it while warming up the track. Do not use excessive throttle during warm-up or when the track is free-hanging.
  • Page 71 OPERATION Fuel 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 72: Fuel Recommendation

    OPERATION Fuel Recommendation For peak performance, POLARIS recommends the use of 91 octane fuel or higher, with no ethanol. Although 87 octane fuel is usable, some engine performance 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.

  • Page 73: Low Oil Level

    NOTICE: Operating the snowmobile without adequate engine lubrication can result in serious engine damage. Always check the oil level when refueling. Add oil as needed. The oil bottle cap is vented to allow proper oil flow. See your POLARIS dealer for recommended replacement parts.

  • Page 74: Engine Stop Switch

    OPERATION Engine Stop Switch Push down on the engine stop switch to ground out the ignition and stop the engine Stop quickly. Pull the switch up to Switch the ON 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 75 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 possible.
  • Page 76 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 transmission if shifting is attempted when the engine is operating above idle speed.
  • Page 77 OPERATION Electronic Reverse (PERC) Engaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Make sure the area behind your vehicle is clear. 3. Push the yellow reverse button on the left-hand control for one second, then release. The engine will automatically reduce RPM and start a reverse rotation.

  • Page 78: Emergency Stopping

    OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 72 for more information about the engine stop switch and throttle safety switch. SYSTEM WHAT IT DOES Ignition Switch Interrupts ignition circuit Brake Slows jackshaft Engine Stop Switch...
  • Page 79 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 inches (10 cm) off the ground. Remove the key and cover the snowmobile.

  • Page 80: Maintenance

    Please read the Snowmobile Engine Emissions Limited Warranty, and read the maintenance section of your owner's manual. You are responsible 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. Non-ionizing Radiation This vehicle emits some electromagnetic energy.
  • Page 81 MAINTENANCE POLARIS Recommended Maintenance Program To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as outlined in this manual. Record maintenance and service in the Maintenance Log beginning on page 133. The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections at 150 miles (240 km), 500 miles (800 km) and 1000 miles (1600 km).
  • Page 82 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 83 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 Brakes Brake System 59, 94 Brake Fluid FUEL MANAGEMENT...

  • Page 84: Suspension Mounting Bolts

    I - Inspect (clean, adjust, tighten, lubricate, replace if necessary) C - Clean R - Replace L - Lubricate Bolt Torque Inspection To maintain proper chassis performance, see your POLARIS dealer for a bolt torque inspection every 1000 miles (1600 km). Item Description Engine Mounting Bolts...
  • Page 85 To remove an open side panel, pull the panel outward to release the tabs at the lower edge of the panel. Removing the hood is not recommended. Any service requiring the removal of the hood should be performed by an authorized POLARIS dealer.

  • Page 86: Rear Suspension

    MAINTENANCE Lubrication Rear Suspension Lubricate the suspension pivot shafts with POLARIS All Season Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 80 and before seasonal storage. When operating in heavy, wet snow conditions, lubricate every 500 miles (800 km).

  • Page 87: Chaincase Oil

    Check and change the chaincase oil at the intervals outlined in the maintenance charts beginning on page 79. Maintain the oil level at the top of the fill plug hole. POLARIS recommends the use of POLARIS Synthetic Chaincase Lube. See page 120 for the part numbers of POLARIS products.

  • Page 88: Spark Plugs

    MAINTENANCE Spark Plugs Spark Plug Recommendations A new engine can cause temporary spark plug fouling due to the preservative added during the assembly process. Avoid prolonged idle speeds, which cause plug fouling and carbonization. Refer to the specifications section for the specific spark plug to be used in your snowmobile.

  • Page 89: Spark Plug Inspection

    MAINTENANCE Spark Plugs Spark Plug Inspection 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.

  • Page 90: Oil Lines

    Do not attempt to service the fuel pump. Fuel Filter/Fuel Lines See your POLARIS dealer for replacement of the fuel filter at the intervals outlined in the Periodic Maintenance Table beginning on page Contaminated or poor quality fuel will shorten the life of the fuel filter and result in poor engine performance.

  • Page 91: Cooling System

    Please see your POLARIS dealer. When adding or changing coolant, POLARIS recommends using POLARIS Antifreeze 60/40 Premix, which is already premixed and ready to use. Do not dilute with water. Never exceed a 60% antifreeze/ 40% water mixture. See page 120 for POLARIS products.

  • Page 92: Engine Overheating

    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 93 MAINTENANCE Cooling System Bleeding the Cooling System CAUTION! Steam and hot liquids will cause 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 94: Exhaust System

    MAINTENANCE Exhaust System Check the exhaust system for wear or damage at approximately 2000 miles (3200 km). Always allow the engine and exhaust system to cool completely before inspecting. CAUTION! Hot exhaust system parts can cause burns. Allow adequate time for the exhaust system to cool.
  • Page 95 MAINTENANCE Drive Chain Tension (RMK/ASSAULT RMK) Check drive chain tension weekly and before each long trip. 1. Remove the side panels. 2. Rotate the driven clutch counter-clockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly.

  • Page 96: Brake Components

    POLARIS dealer for inspection and adjustment. TIP: The PRO RMK and RMK ASSAULT models are equipped with a lightweight brake disc that has vent holes. These holes may cause a high-pitched...

  • Page 97: Brake Fluid

    If the fluid is sufficient, the sight glass will be black. If the sight glass is any color other than black, add brake fluid. Replace brake fluid at least every two years with POLARIS DOT 4 high temperature brake fluid. See page 120 for the part numbers of POLARIS products.
  • Page 98 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 99: Headlight Lamp Replacement

    MAINTENANCE Lights When servicing a halogen lamp, avoid touching the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do touch a lamp, clean it with denatured alcohol.
  • Page 100 POLARIS dealer. Any unauthorized modifications to clutches, such as adding or removing weights, will void the warranty. NOTICE: The bushings in the weights and rollers of POLARIS clutches are made of a material that may be damaged if lubricated. Do not lubricate clutch bushings.

  • Page 101: Drive Belt Condition

    Special tools are required to remove and install the QUICKDRIVE belt. Please see your POLARIS dealer for this service, or refer to the instructions provided with the purchase of a new belt. Improper track tension can result in track ratcheting, which will affect QUICKDRIVE belt durability.

  • Page 102: Drive Belt Deflection

    MAINTENANCE Clutch System Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge (1) on the belt and apply downward pressure while measuring at point 2. This measurement should be 1 1/4 inches (3.2 cm).

  • Page 103: Drive Belt Removal

    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. Rotate the driven clutch counter- clockwise 1/4 turn by hand to ensure forward engagement before attempting to remove the belt.

  • Page 104: Drive Belt Installation

    MAINTENANCE Clutch System Drive Belt Installation 1. With the L-wrench inserted into the threaded hole and the sheaves in the open position, install the drive belt. TIP: Install the belt so that the numbers can be read correctly on the left side of the vehicle, or in the direction in which the belt was originally installed.
  • Page 105 MAINTENANCE Track Maintenance Track Inspection WARNING! Broken track rods can cause a rotating track to come off the snowmobile, which could cause serious injury or death. Never 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.

  • Page 106: Track Tension

    MAINTENANCE Track Maintenance 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 Track adjustment is critical for proper handling.
  • Page 107 MAINTENANCE Track Maintenance Track Tension 5. Check for specified slack between the wear surface of the track clip and the plastic slider. Refer to the Track Tension Data Chart on page 104. If the track needs adjustment: 6. Loosen the rear idler shaft bolt. 7.

  • Page 108: Track Alignment

    MAINTENANCE Track 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 109: Steering Inspection

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

  • Page 110: 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. 1. Place the handlebars in a straight-ahead position.

  • Page 111: Ski Skags

    MAINTENANCE Steering System 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 112: Rail Slide Wear

    MAINTENANCE Steering System Rail Slide Wear For ease of inspection, all POLARIS rail slides have a wear limit indicator Minimum groove to indicate the Thickness minimum permissible slide thickness. Replace the rail slides if they are worn to the top of the groove at any point along their length.
  • Page 113 MAINTENANCE Battery (if equipped) WARNING! Improperly connecting or disconnecting battery 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 negative (black) cable last. Battery Removal 1.
  • Page 114 Check battery voltage each month during storage and recharge as needed to maintain a full charge. Tip: Battery charge can be maintained by using a POLARIS Battery Tender charger or by charging about once a month to make up for normal self- discharge.
  • Page 115 MAINTENANCE Battery Battery Charging For a refresh charge, follow all instructions carefully. 1. Check the battery voltage with a voltmeter or multimeter. A fully charged battery will register 12.8 V or higher. 2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until the battery voltage is 12.8 or greater.

  • Page 116: Transporting The Snowmobile

    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 120 for the part numbers of POLARIS products. Cleaning and Preservation Proper storage starts with cleaning, washing, and waxing the hood, side panels, chassis, and plastic parts.

  • Page 117: Controls And Linkage

    MAINTENANCE Extended Storage Controls and Linkage Lubricate all bushings and cables as outlined in the Periodic Maintenance Table beginning on page 80. Clutch and Drive System Remove the drive belt and store in a cool dry location. Do not lubricate clutch components, except the driven clutch shaft bushing as outlined in the Master Repair Manual.

  • Page 118: Specifications

    SPECIFICATIONS 600 RMK / 600 PRO RMK Capacities and Dimensions Body Style PRO-RIDE Rider Capacity Coolant Capacity 6 qts. (5.7 l) (RMK 144) 6.3 qts. (6.0 l) (RMK 155) 5.3 qts. (5.0 l) (PRO RMK 155) Chaincase Oil Capacity 9 oz. (266.2 ml) (600 RMK) N/A (600 PRO RMK) Fuel Tank Capacity 11.5 gal.
  • Page 119 SPECIFICATIONS 600 RMK 144 / 600 RMK 155 Clutching Chart ALTITUDE Drive Drive Driven Driven Chaincase Meters Clutch Shift Clutch Clutch Helix Gearing/Pitch (Feet) Weight Spring Spring Factory settings for North America Factory settings for International LH BLK/PUR (56/42/.36) 0-450 10-64 Black/Green 20:42...
  • Page 120 SPECIFICATIONS 800 RMK / 800 PRO RMK / 800 RMK ASSAULT Capacities and Dimensions Body Style PRO-RIDE Rider Capacity Coolant Capacity 6.3 qts. (6.0 l) (RMK 155) 5.3 qts. (5.0 l) (PRO RMK 155) 5.3 qts. (5.0 l) (RMK ASSAULT 155) 5.5 qts.
  • Page 121 SPECIFICATIONS 800 RMK 155 / 800 RMK ASSAULT 155 Clutching Chart ALTITUDE Drive Drive Driven Driven Chaincase Meters Clutch Shift Clutch Clutch Helix Gearing/Pitch (Feet) Weight Spring Spring Factory settings for North America Factory settings for International LH BLACK (56/42/.36) 0-600 10-68 140/330...

  • Page 122: Polaris Products

    All Season Grease (3 oz./89 ml cartridge) 2871423 All Season Grease (14 oz./414 ml cartridge) 2871329 Dielectric Grease (Nyogel™) Coolant 2871534 Polaris Antifreeze 60/40 Premix (qt./.95 l) 2871323 Polaris Antifreeze 60/40 Premix (gal./3.8 l) Additives/Miscellaneous 2871326 Carbon Clean 2870652 Fuel Stabilizer...

  • Page 123: Troubleshooting

    TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Erratic engine RPM Drive clutch binding • SEE YOUR DEALER. during acceleration Driven clutch • SEE YOUR DEALER. or load variations malfunction Engine doesn't turn Seized engine • SEE YOUR DEALER. Seizure is a result of poor lubrication, inadequate fuel supply, broken parts or improper cooling.
  • Page 124 TROUBLESHOOTING Drive System Troubleshooting Problem Probable Cause Solution Machine fails to Clutch jammed • Check for twisted belt or broken move spring. SEE YOUR DEALER. Track jammed • Foreign object may be caught or the rail slide melted to the track clips due to lack of lubrication.
  • Page 125 TROUBLESHOOTING Drive Belt Troubleshooting Belt Wear/Burn Diagnosis Causes Solutions Driving at low RPM • Drive at higher RPMs. Gear the machine down. Check belt deflection. Insufficient warm-up • Warm the engine at least five minutes. Take the drive belt off the snowmobile in extremely cold weather and warm it up.
  • Page 126 TROUBLESHOOTING Suspension Troubleshooting Problem Solution Rear suspension • Refer to the suspension adjustment and set-up information bottoms too easily beginning on page 50. • Revalve rear track shock (see your dealer). Rides too stiff in rear • Refer to the suspension adjustment and set-up information beginning on page 50.

  • Page 127: Warranty

    Service and Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the POLARIS warranty information contained in this manual. Contact your POLARIS dealer for replacement parts, service or warranty. Your dealer receives frequent updates on changes, modifications and tips on snowmobile maintenance, which may supersede information contained in this manual.
  • Page 128 This warranty is transferable to another owner during the warranty period through a POLARIS dealer, but any such transfer will not extend the original term of the warranty. The duration of this warranty may vary by international region based upon local laws and regulations.
  • Page 129 Warranty Coverage and Exclusions Limitations of Warranties and Remedies This POLARIS Limited Warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God, accidental damage, normal wear and tear, abuse or improper handling.
  • Page 130 MATERIALS, COMPONENTS, OR PRODUCTS. THE REMEDIES SET FORTH IN THIS WARRANTY ARE THE ONLY REMEDIES AVAILABLE TO ANY PERSON FOR BREACH OF THIS WARRANTY. POLARIS SHALL HAVE NO LIABILITY TO ANY PERSON FOR INCIDENTAL, CONSEQUENTIAL OR SPECIAL DAMAGES OF ANY DESCRIPTION, WHETHER ARISING OUT OF EXPRESS OR IMPLIED WARRANTY OR ANY OTHER CONTRACT, NEGLIGENCE, OR OTHER TORT OR OTHERWISE.
  • Page 131 If you purchase from a private party: If you purchase a POLARIS product from a private party, to be kept and used outside of the country in which the product was originally purchased, all warranty coverage will be denied.
  • Page 132 SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give authorization for export. You should consult an authorized dealer to determine this product’s warranty or service coverage if you have any questions.
  • Page 133 U.S.A. EPA Emissions Limited Warranty 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 applicable U.S.
  • Page 134 POLARIS dealer to perform any service that may be necessary for your vehicle. POLARIS also recommends that you use only 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 135: Maintenance Log

    MAINTENANCE LOG Present this section of your manual to your dealer each time your snowmobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM) 150 mi.
  • Page 136 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)

  • Page 137: Index

    INDEX Accessories ....30 DET..... . . 32-33 Air Pollution .
  • Page 138 Instrument Cluster ... . 34-49 Polaris Products and Part Numbers . 120 Intake Filters ....88 Pre-Ride Checklist.
  • Page 139 INDEX QUICKDRIVE Belt ... . . 29 Survival Preparation ... . . 12 Suspension Adjustments ..50-54 Suspension Inspection, Pre-Ride .
  • Page 140 For your nearest Polaris dealer, call 1-800-POLARIS (765-2747) or visit www.polaris.com Polaris Industries Inc., 2100 Hwy. 55, Medina, MN 55340 Part No. 9925091 Rev 01 Printed in USA *9925091...

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