Polaris Trail RMK Owner's Manual
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Polaris Trail RMK Owner's Manual

Polaris Trail RMK Owner's Manual

Polaris 2010 snowmobile owner's manual
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Pantone 426C
Trail RMK
Snowmobile Owner's Manual
for Maintenance and Safety

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Summary of Contents for Polaris Trail RMK

  • Page 1 Pantone 426C Trail RMK Snowmobile Owner's Manual for Maintenance and Safety...
  • Page 2 Pantone 426C For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 Phone 1-888-704-5290 Part No. 9922282 Rev 01 Printed in USA...
  • Page 3 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. 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 2009 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..... . . 109 Suspension Troubleshooting ... . 110 Troubleshooting .

  • 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. When teaching inexperienced operators to ride, set up a predetermined course for practice.

  • Page 9: Preservation Of The Environment

    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: 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 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, indicates the potential for serious injury.

  • Page 12: Operator Safety

    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 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: Survival Preparation

    Operator Safety Survival Preparation For your safety, always ride in a group of other snowmobilers. Always tell someone where you’re going and how long you expect to be gone. If it isn’t possible to ride with others, and you must travel into remote areas, always carry survival equipment that’s appropriate to the condi- tions you may encounter.

  • Page 15: Riding Apparel

    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...

  • Page 16: Disabled Operators

    SAFETY Operator Safety Cargo Overload Too much weight on the rear of the machine may reduce your ability to steer. Do not exceed carrier and rack weight limits, and do not allow a passenger to sit on the seat back or the cargo carrier. Disabled Operators Safe operation of this rider-active vehicle requires good judgement and physical skills.

  • Page 17: 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 18 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: Ice And Snow Build-Up

    SAFETY Operator Safety Ice and Snow Build-up 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. If difficulty is encountered, check for ice and snow build-up that may be obstructing the steering linkage.

  • Page 20: Driving In Hilly Terrain

    SAFETY Operator Safety Driving in Hilly Terrain WARNING! Climbing a hill or crossing the face of a slope may result in loss of balance and machine roll-over, causing serious injury or death. Use caution and good judgement when driving in hilly terrain. Operating in hilly terrain requires extreme caution to maintain balance and avoid roll-over.

  • Page 21: Driving Downhill

    SAFETY Operator Safety Driving Downhill When riding downhill, shift your weight to the rear of the machine 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 machine and keep it from rolling freely downhill.

  • Page 22: Intake Silencer

    SAFETY Operator Safety Intake Silencer Do not operate the engine with the intake silencer or filter removed. Damage to the engine may occur if the intake silencer or filter are removed. Clutches Do not attempt to service the clutches. All clutch service must be performed by your dealer. The clutch is a complex mechanism that rotates at high speeds.

  • 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 machine. 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

    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 Speed Calm Frostbite in >> 30 min. WIND CHILL CHART (°C) Wind Speed Calm -11 -14 -18 -22 -25 -29 -32 -36 -39 -43 -46 -50 -53 -57 -10 -13 -17 -21 -24 -28 -32 -36 -39 -43 -47 -50 -54 -58 -62 -11 -15 -19 -22 -26 -30 -34 -38 -42 -45 -49 -53 -57 -61 -65...

  • 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/Seat Warning

    Entanglement with the track or a fall from seat back may result in severe injury or death. Reverse Warning Polaris snowmobiles equipped with electric reverse and will have this decal on the console: WARNING Reverse operation, even at low...

  • Page 28: Operation Warning

    Safety Decals and Locations Operation Warning An operation warning decal is present 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. If manual is missing, con- tact a Polaris dealer for a replacement.

  • Page 29: Features And Controls

    FEATURES AND CONTROLS 1. Fuel Filler Cap (may include a fuel gauge) 2. Ignition Switch 3. Brake Lever 4. Speedometer (may include indicator/warning lights) 5. Reverse Indicator 6. Mountain Bar (accessory) 7. Engine Stop Switch (see page 58) 8. Throttle Control 9.

  • Page 30: Fuel Valve

    Some Polaris snowmobiles are equipped with special features. Controls for these features are illustrated on this page. Not all models come with these features. See your Owner’s Manual Supplement. Tip: Accessories are available from your Polaris dealer. 1. Headlight Dimmer Switch 2.
  • Page 31 FEATURES AND CONTROLS 1. Hood 2. Headlight 3. Windshield 4. Handlebar 5. Operator Seat 6. Storage Compartment 7. Taillights 8. Snow Flap 9. Track 10. Suspension 11. Trailing Arm 12. Nosepan 13. Front Bumper (do not use for pulling or dragging the snowmobile) 14.

  • Page 32: The Perfect Fit

    THE PERFECT FIT Front Suspension Adjustments Break in the suspension for approximately 150 miles (240 km) and re- grease all suspension parts 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 33: Shock Components

    IFS. See page 98 to check alignment. Do not attempt to change the ski alignment or camber adjustment. See your Polaris dealer. The tension at which the shock coil spring is set is called spring preload.

  • Page 34: Front Suspension Adjustments

    Front Suspension Adjustments Front Springs For models without externally adjustable or revalvable shocks, the front springs can be changed if spring preload alone isn’t sufficient and fur- ther adjustment is desired to control suspension stiffness. See your Polaris dealer for more information.

  • Page 35: Shock Spring Preload

    THE PERFECT FIT Front Suspension Adjustments Shock Spring Preload Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-to-ground pressure. When adjusting, be sure the springs on both the left and right sides of the machine are at the same adjustment. To increase front shock spring pre- load, grasp the spring and turn it to the right.

  • Page 36: Rear Suspension Adjustments

    Bogie wheel kits are available from your dealer. • Polaris offers track kits for improved flotation in deep snow. See your dealer for assistance. Tip: Keep the suspension pivot points lubricated. This will reduce moisture and rust build-up and ensure proper function of the suspension components.
  • Page 37 THE PERFECT FIT Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method) To set up the EDGE RMK rear suspension torsion spring preload, mea- sure the distance between the ground and rear bumper (see illustration). This measurement should be taken with no rider and the rear suspension at full extension.
  • Page 38 THE PERFECT FIT Rear Suspension Adjustments Initial Spring Preload Setting (Sag Method)) To determine sag, commonly referred to as ride-in, subtract measure- ment Y from X (sag=X-Y). Adjust sag by rotating the torsion spring preload cams located on the rear torque arm. Use the illustration for ref- erence.

  • Page 39: 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. See your dealer for more information.

  • Page 40: Shock Compression Damping

    Rear Suspension Adjustments Shock Compression Damping Your snowmobile is equipped with the Indy Select rear shock, which allows for adjustments to the compression valving. 1. Locate the adjustment screw near the base of the shock. 2. Adjust the screw 1/2 turn clockwise to increase compression valv- ing and stiffen the ride.

  • Page 41: Handlebar Adjustments

    THE PERFECT FIT Handlebar Adjustments Standard Handlebar Follow these steps to adjust handlebar angle at the handlebar block. 1. Remove the handlebar cover to expose the handlebar and the four adjuster block bolts. 2. Using a 7/16-inch wrench, loosen the four nuts on the bottom of the adjuster block (turn the handlebar either left or right for access to the rear...
  • Page 42 Accessories Polaris offers a wide range of accessories for your snowmobile. From map light to electric start, Polaris has the accessories that will help make each ride more enjoyable. See your dealer for a list of accessories. Use only Polaris parts and accessories on your Polaris snowmobile. Use of unapproved parts and accessories may result in: •...

  • Page 43: Traction Products

    THE PERFECT FIT Traction Products Another way to tailor your machine is to install traction products. See your dealer about installing studs and/or carbides. Many tracks with deep lug designs cannot be studded, but your dealer will be able to offer advice and assistance.
  • Page 44 Center of stud must be at least 1 1/8 inches (2.86 cm) from the outside edge of the track. Use only Polaris traction products on your snowmobile. Track warran- ties are void if track damage or failure results from improper or exces- sive stud installation or the use of non-Polaris traction products.

  • Page 45: Wear Strips

    THE PERFECT FIT Traction Products Wear Strips To avoid excessive tunnel or cooler damage, wear strips must be installed whenever track studding is used. See your dealer for more information. Wear strips are designed for a specific stud length. See your dealer’s studding chart for recommended traction accessories.

  • Page 46: 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 ( locate the pre-ride inspection items Drive Belt Condition Steering System Recoil Rope Parking Brake Lock/Brake Lever/Brake System...

  • Page 47: 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 48: Lever Feel

    PRE-RIDE INSPECTIONS Before Starting the Engine n Brakes Properly functioning brakes are critical to your safety. Always check the following items to assure proper operation before starting the engine. Brake Lever Travel Squeeze the brake lever. It should move no closer to the handgrip than 1/2 inch (1.3 cm).

  • Page 49: Parking Brake Lever Lock

    PRE-RIDE INSPECTIONS Before Starting the Engine n Parking Brake Lever Lock Your snowmobile may have a parking brake lever lock located over the brake lever. Use the brake lever lock only when you want the machine to remain sta- tionary; for example, when parked on an incline for a period of five minutes or less.

  • Page 50: 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 51: Ignition Switch

    PRE-RIDE INSPECTIONS Start the Engine and Check Engine Stop Switch Check the auxiliary shut-off switch for proper operation. Push the switch down to stop the engine. Pull it up to allow restarting. Lighting Check the headlight (high and low beam), taillight, and brake light. Replace burned out lamps before operating.

  • Page 52: 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 fuel valve on. See page 27.

  • Page 53: Engine Break-In

    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 54: Oil Injection System

    Oil Recommendations Engine lubrication comes from oil added to the fuel and oil injection systems. Polaris recommends the use of Premium 2-Cycle Oil for this engine. See page 109 for the part numbers of Polaris products. Never mix brands of oil. Serious chemical reactions can cause injection system blockage, resulting in serious engine damage.
  • Page 55 OPERATION Track Warm-Up WARNING! Use of traction products such as studs, ice growsers, etc. will increase the possibility of track damage and/or failure. This could cause loss of control, resulting in serious injury or death. Always inspect for track damage before operating the snowmobile.

  • Page 56: Slide Rail And Track Cooling

    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. Avoid operating on ice, hard-packed surfaces or roads.

  • Page 57: Fuel Recommendations

    OPERATION Fuel Fuel Recommendations Your Polaris engine is designed to run on 87 octane non-oxygenated or 89 octane oxygenated pump gasoline. There’s a great deal of variability in the quality of the 87 octane gasoline available, so we encourage the use of premium fuel when possible.

  • Page 58: Low Oil Indicator Light

    Always check the oil level when refu- eling. Add oil as needed. The Polaris oil cap on the oil bottle may be vented to allow proper oil flow. See your Polaris dealer for recommended replacement parts.
  • Page 59 OPERATION Carburetion Proper carburetor adjustment is critical. Always have your Polaris dealer perform any carburetor adjustments. A lean mixture (too much air, too little fuel) may result in piston burn- ing, bearing failure, or complete engine failure. A rich mixture (too much fuel, too little air) may foul plugs and cause generally poor engine performance.

  • Page 60: Jetting Guidelines

    Carburetion Jetting Guidelines Changes in altitude and temperature affect air density, which is the amount of oxygen available for combustion. In low elevations and cold temperatures, the air has more oxygen. In higher elevations and higher temperatures, the air is less dense. RMK carburetors are preset to operate at altitudes of 6000-8000 feet (1800-2400 m) above sea level (see page 78 for more information).

  • Page 61: Engine Stop Switch

    OPERATION Engine Stop Switch Push down on the engine stop switch to stop the engine in an emergency. This will ground out the ignition and bring the engine to a quick stop. To restart the engine, the switch must be pulled up to the ON position.

  • Page 62: 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 machine with the throttle safety switch disconnected. Return the machine to an authorized Polaris dealer for service as soon as possible. OPERATION...

  • Page 63: Emergency Stopping

    OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. Refer to page 58 for more information about the engine stop switch and throttle safety switch. SYSTEM Ignition Switch Brake Choke Engine Stop Switch Throttle Safety Switch WARNING! Excessive or repetitive use of brakes for high speed stops will cause an overheated brake system.
  • Page 64 Electronic Reverse (PERCt) Electronic reverse will activate only if the engine is below 4000 RPM. If your machine is running at an altitude of over 6000 feet, adjust the igni- tion setting as described on page 62. Always make sure the vehicle is stopped and the engine is running at idle before shifting to reverse.
  • Page 65 OPERATION Electronic Reverse (PERCt) Disengaging Reverse 1. Stop the snowmobile and leave the engine idling. NOTICE: Engaging the starter when the engine is running WILL result in serious engine damage, especially if the transmission is in reverse. Never engage the starter when the engine is running. 2.
  • Page 66 Towing Do not use the front bumper to pull or drag the snowmobile. The front bumper is not designed for this type of use and may detach from the vehicle if force is applied. For your safety, do not attempt to using the tow hitch until you’ve read the following warnings and understand the proper hitch functions.

  • Page 67: 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...
  • Page 68 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 69 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 Clutch Offset Alignment...
  • Page 70 Periodic Maintenance Interval Table Item Hose Routing Hose Condition Fluid Leaks Brake Pads Brake Disc Parking Brakes Brake System Brake fluid Pilot Air Screws Carburetor (synchronize) Idle RPM Throttle Lever Oil Pump Lever (synchronize) Throttle Cable Choke Cable Vent Lines Throttle Position Sensor Choke Fuel Filter...

  • Page 71: Suspension Mounting Bolts

    MAINTENANCE Periodic Maintenance Interval Table Item Auxiliary Shut-Off Switch Throttle Safety Switch Ignition Switch Taillight Brakelight Headlight Ski Toe Alignment Suspension Mounting Bolts Steering Fasteners Rear Suspension Fasteners Suspension Shock Oil Cooling Fins and Shroud Drive Shaft Bearings Skags (Wear Bars) Ski Saddle/Spindle Bolts Ski Pivots Ski Spindle...

  • Page 72: Track Alignment/Condition

    Periodic Maintenance Interval Table Item Rear Suspension Pivot Shafts Camber Alignment Radius Rod Bushings Handlebar Centering Track Alignment Track Tension Front Limiter Strap Rail Slide Condition Chaincase Oil Gearcase Oil I - Inspect (clean, adjust, tighten, lubricate, replace if necessary) C - Clean R - Replace Page...

  • Page 73: Front Suspension

    MAINTENANCE Lubrication Front Suspension Lubricate the suspension and steering components with Polaris Pre- mium All-Season Grease at 500 miles (800 km) and annually or every 1000 miles (1600 km) thereafter. See page 109 for the part numbers of Polaris products.

  • Page 74: Rear Suspension

    MAINTENANCE Lubrication Rear Suspension The suspension pivot shafts should be lubricated with Polaris Premium All Season Grease at 500 miles (800 km) initially, every 1000 miles (1600 km) after that, and before off-season storage each year. Lack of lubrication will adversely affect your ride and the life of the suspension.

  • Page 75: Throttle Cable

    MAINTENANCE Lubrication Jackshaft Bearing The jackshaft bearing on your model may be equipped with a grease fit- ting, but this component is greased for life at the factory. Additional lubrication is not required. Driveshaft Bearing Inject grease into the fitting on the speedometer drive adaptor until grease purges from inside or outside the bearing seal (approximately two...

  • Page 76: Chaincase Oil Level

    Maintain the oil level between the “safe” marks on the dipstick. Clean the magnetic plug on the dipstick whenever checking or changing oil. Polaris recommends the use of Polaris Synthetic Chaincase Lube. See page 109 for the part numbers of Polaris products.

  • Page 77: Spark Plugs

    MAINTENANCE Spark Plugs It’s very important to use the correct spark plug for your machine. A spark plug with a heat range too high will cause engine damage. A spark plug with a heat range too low will cause excessive fouling and engine malfunctioning.
  • Page 78 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 79: Intake Filter

    MAINTENANCE Intake Filter The intake foam filter and screen limits snow ingestion into the intake system. When operating in loose powder snow, check the top of the foam filter and screen periodically to remove any accumulation of snow. NOTICE: Operating the snowmobile with the intake filters removed may cause carburetor icing.
  • Page 80 Carburetor Water/Sediment Trap Service 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 81: Carburetor Adjustments

    It’s your dealer’s responsibility to make sure the correct main jet is installed. NOTICE: 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 82: Oil Filter

    Fuel Filter/Fuel Lines The fuel filter is located inside the fuel tank. This component requires no maintenance. Inspect the fuel lines regularly for signs of deterioration or damage. Always check fuel line condition after periods of storage. Normal dete- rioration from weather and fuel compounds may occur. Replace worn or damaged fuel lines promptly.

  • Page 83: Exhaust System

    MAINTENANCE Exhaust System Check the exhaust system for wear or damage at approximately 1000 miles (1600 km). To inspect, allow the engine and exhaust system to cool completely. Open the hood and inspect the muffler and pipes for cracks or damage. Check for weak or missing retaining springs or damper/support grommets.

  • Page 84: Hydraulic Brake Inspection

    Brakes n Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 45. Brake pads must be replaced when the brake pad material becomes thin- ner than the backing plate (approximately 1/16 inch/1.5 mm). A kit is available for replacing brake pads.

  • Page 85: Brake Fluid

    We recommend the use of Polaris DOT 4 high temperature brake fluid. See page 109 for the part numbers of Polaris products. NOTICE: Brake fluid will damage decals, paint and some plastics. Always wipe up spills immediately.

  • Page 86: Bleeding The Hydraulic Brake System

    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. Never operate the vehicle with a spongy-feeling brake lever.

  • Page 87: Headlight Adjustment

    MAINTENANCE Lights Headlight Adjustment The headlight may be adjusted for vertical aim using the following pro- cedure: 1. Place the snowmobile on a level surface with the headlight approxi- mately 25 feet (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the headlight and make a mark on the wall.

  • Page 88: Removing Halogen Bulbs

    Lights NOTICE: Avoid touching 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. Removing Halogen Bulbs 1.

  • Page 89: Clutch System

    Any unauthorized modifications to clutches, such as adding or remov- ing weights, will void the warranty. 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 90: Drive Belt Condition

    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 91: Drive Belt Removal

    MAINTENANCE Clutch System Drive Belt Removal 1. Stop the engine after operating in a forward motion. 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.

  • Page 92: Drive Belt Installation

    Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. Tip: To ensure satisfactory belt life, install belts so they operate in the same direction of rotation by positioning the identification numbers so that you can read them.

  • Page 93: Drive Belt Deflection

    MAINTENANCE Clutch System n Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge on the belt (1) and apply downward pressure while measuring at point 2. This measurement should be 1 1/4 inches (32 mm).

  • Page 94: Tool Kit

    Always keep the tool kit with the snowmobile. Chain Tension Maintain the proper chain tension as outlined on page 80. Fall Tune-Up For maximum performance, arrange for a fall service tune-up with your Polaris dealer.

  • Page 95: Track Inspection

    MAINTENANCE Track Track Inspection WARNING! Broken track rods can cause a rotating track to come off the machine, 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 96: Track Lubrication

    Track 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 little or no snow for lubrication.
  • Page 97 MAINTENANCE Track 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 Track adjustment is critical for proper handling.
  • Page 98 Track Track Tension f the track needs adjustment: 6. Loosen the rear idler shaft bolt. 7. Loosen the locknuts. 8. Tighten or loosen the track adjusting screws as necessary to pro- vide equal adjustment on both sides of the track. 9.

  • Page 99: Track Alignment

    MAINTENANCE Track n 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 machine with the track off the ground.

  • Page 100: Steering Inspection

    MAINTENANCE Steering System Steering Inspection Each week, or before a long ride, check fasteners and tighten if neces- sary. Specific fasteners that should be checked are marked with a the illustration.

  • Page 101: 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 102: Ski Skags

    MAINTENANCE Steering System n Ski Skags 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 con- trol while turning on hard-packed snow or ice.

  • Page 103: Rail Slide Wear

    MAINTENANCE Suspension Maintenance n Rail Slide Wear For ease of inspection, all Polaris rail slides have a wear limit indicator groove to indicate the minimum per- missible slide thickness. Replace the rail slides if they are worn to the top of the groove at any point along their length.

  • Page 104: Battery Fluid

    Battery WARNING Battery electrolyte is poisonous. It contains acid! Serious burns can result from contact with the skin, eyes, or clothing. If contact occurs, seek immediate medi- cal attention. KEEP OUT OF REACH OF CHILDREN. EXTERNAL: Flush with water. INTERNAL: Drink large quantities of water or milk. Call physician immediately. EYES: Flush with water for 15 minutes and get prompt medical attention.

  • Page 105: Battery Removal

    MAINTENANCE Battery Battery Connections Keep battery terminals and connections free of corrosion. When clean- ing is necessary, remove the corrosion with a stiff wire brush. Wash ter- minals and connections with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water and dry with clean shop towels.

  • Page 106: Battery Installation

    Battery Battery Installation WARNING! Battery electrolyte contains acid. Avoid skin contact with electrolyte as severe burns may result. Using a new battery that has not been fully charged can damage the bat- tery and result in a shorter life. It can also hinder vehicle performance. 1.

  • Page 107: Battery Storage

    MAINTENANCE Battery Battery Storage When your snowmobile is placed in storage for one month or more (in summer or in winter): • Remove the battery. • Charge it to the proper level. • Store it in a cool dry place. •...

  • Page 108: Daily Storage

    The track should be suspended approximately 4 inches (10 cm) off the ground. Remove the key and cover the machine. Tip: Polaris has accessory covers and track stands available to fit all models. See your dealer for more information.

  • Page 109: Cleaning And Preservation

    MAINTENANCE 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. Cleaning and Preservation Proper storage starts with cleaning, washing, and waxing the hood, chassis, and plastic parts. Wipe down remaining surfaces with a damp cloth.

  • Page 110: Controls And Linkage

    (BDC), the lowest position in the cylinder. On twin cyl- inder models, the opposite piston will be up. 5. Pour approximately two ounces of Polaris injector oil into the spark plug hole. 6. Wait one to two minutes and perform steps 3 to 5 on remaining cyl- inders.

  • Page 111: Electrical Connections

    Separate electrical connector blocks and clean corrosive build-up from connectors. Lubricate or pack connector blocks with dielectric grease and re-connect. See page 109 for the part numbers of Polaris products. 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.

  • Page 112: Polaris Products

    Additives / Miscellaneous 2871326 Carbon Clean Plus (12 oz.) 2870652 Fuel Stabilizer (16 oz.) 2872189 DOT 4 Brake Fluid (12 oz.) 2872893 Engine Degreaser (12 oz.) 2870505 Isopropyl 2872889 Brake and Clutch Cleaner 2872890 Carb and Throttle Body Cleaner POLARIS PRODUCTS Description...

  • Page 113: Suspension Troubleshooting

    SUSPENSION TROUBLESHOOTING Problem Rear suspension bot- • Verify sag dimension (see page 34). Adjust torsion spring toms too easily blocks or install optional torsion springs to achieve correct sag dimensions. • Increase shock compression damping (see page 37). Rear suspension •...

  • Page 114: Troubleshooting

    Belt Wear/Burn Troubleshooting Causes Driving at low RPM Insufficient warm-up Towing at low RPM Riding with high RPM and slow speed (8000 RPM/10 MPH) Ice and snow build-up between track and tunnel Poor engine performance Loading machines onto trailers Clutch malfunction Slow, easy clutch engagement TROUBLESHOOTING...
  • Page 115 TROUBLESHOOTING Engine Troubleshooting CAUTION: Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Probable Cause Erratic engine Drive clutch binding operating RPM during acceler- ation or load variations Driven clutch malfunction Harsh drive Drive belt worn or too clutch engage-...
  • Page 116 Engine Troubleshooting Problem Probable Cause Noise in drive Broken drive clutch system components Bearing failure/ chain- case, jackshaft, or front drive shaft Drive belt surface flat spots Drive chain loose or worn, sprocket teeth broken Poor low RPM Worn drive belt performance Excessive belt/sheave clearance...
  • Page 117 Check tank level and fill up with cor- rect fuel. • Ice in fuel line, filter, or pump. On the standard Polaris carburetor, the choke will not function with the throttle depressed. See second item under “Probable Cause” of “Engine contin- ually backfires”.

  • Page 118: 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 119 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 120: 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 121: 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 122 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 123 • 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 124 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 125 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 126 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 127: 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 (KM) 150 mi.
  • Page 128 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)
  • Page 129 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)
  • Page 130 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)

  • Page 131: Index

    INDEX Accessories ....39 Air Box Warning ....23 Air Pollution .
  • Page 132 Periodic Maintenance Table ..66-69 Polaris Products ....109 Pre-Ride Checklist ....43 Pre-Ride Inspections .
  • Page 133 INDEX Storage, Daily ....105 Storage, Extended ..106-108 Survival Preparation ... . 11 Suspension Adjustments, Front .

This manual is also suitable for:

2010 trail rmk

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