Polaris 600 HO RMK 155 User Manual

7INTRODUCTIONVehicle Identification NumbersRecord your snowmobile’s identification numbers and key number in the spaces provided below. The key number

97MAINTENANCEClutch Systemn Drive Belt ConditionPeriodically check the condition and tension of the drive belt, and always carry a spare. Inspect the

98MAINTENANCEClutch SystemDrive Belt Removal1. Stop the engine after operating in a forward motion.NOTE: For easier accessibility, make sure the clutc

99MAINTENANCEClutch SystemDrive Belt Installation1. Drop the drive belt over the drive clutch and pull back the slack. NOTE: To ensure satisfactory be

100MAINTENANCETrack ReplacementWhen replacing the track, always install a track having the lug size rec-ommended for your model. See your Polaris deal

101MAINTENANCETrack LubricationThe slide rail requires adequate snow cover for sufficient lubrication. Excessive wear indicates insufficient lubricati

102MAINTENANCETrack TensionTrack adjustment is critical for proper handling. Always maintain cor-rect tension and alignment.NOTE: Tension adjustments

103MAINTENANCETrack Tension If the track needs adjustment:5. Loosen the rear idler shaft bolt.6. Loosen the lock nuts.7. Tighten or loosen the track a

104MAINTENANCEn Track AlignmentPeriodically check that the track is centered and running evenly on the slide rails. Misalignment will cause excessive

105MAINTENANCESteering SystemSteering Inspection and AdjustmentCheck all steering system fasteners weekly and before a long ride. Tighten any loose fa

106MAINTENANCESteering SystemSki AlignmentWith the handlebars in a straight ahead position, and with vehicle weight compressing the suspension, measur

8SAFETYOperator SafetyThe following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these wor

107MAINTENANCESteering Systemn Ski SkagsCheck skags before each use of the snowmobile to ensure positive steer-ing characteristics. Skags must be repl

108MAINTENANCESteering Systemn Rail Slide WearFor ease of inspection, all Polaris rail slides have a wear limit indicator groove to indicate the minim

109MAINTENANCEExtended StorageOff-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolo

110MAINTENANCEExtended StorageEngine and Carburetor Protection (600 RMK)Proper preparation of the engine and fuel system is vital to the preven-tion o

111MAINTENANCEExtended StorageElectrical ConnectionsReplace worn or frayed electrical wire and connectors. Be sure wiring harness is properly secured

112POLARIS PRODUCTSPart No. DescriptionEngine Lubricants2870791 Fogging Oil (12 oz. Aerosol)2871098 Premium 2-Cycle Engine Oil (qt.)2871097 Premium 2-

113TROUBLESHOOTINGEngine TroubleshootingUnless you have experience and training in two-cycle engine repair, see your dealer if technical problems aris

114TROUBLESHOOTINGEngine TroubleshootingProblem Probable Cause SolutionNoise in drive sys-temBroken drive clutch components• SEE YOUR DEALER.Bearing f

115TROUBLESHOOTINGEngine TroubleshootingProblem Probable Cause SolutionEngine turns but fails to startFaulty ignition • Install new spark plug(s). If

116TROUBLESHOOTINGSuspension TroubleshootingProblem SolutionRear suspension bot-toms too easily • Set static sag (see page 43). Adjust torsion spring

9SAFETYOperator SafetyFollow the recommended maintenance program outlined beginning on page 71 of this manual to ensure that all critical components o

117TROUBLESHOOTINGDrive Belt TroubleshootingBelt Wear/Burn DiagnosisCauses SolutionsDriving at low RPM • Drive at higher RPM. Gear the machine down. C

118WARRANTYService And Warranty InformationObtaining Service and Warranty AssistanceRead and understand the service data and the Polaris warranty info

119WARRANTYService And Warranty InformationPolaris Anti-Theft SystemThe Polaris anti-theft system (PATS) monitoring program is designed to aid owners

120WARRANTYLimited WarrantyPolaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM-ITED WARRANTY on all components of the Polar

121WARRANTYLimitations of warranties and remediesALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FI

122WARRANTYConditions and ExclusionsIn order to qualify for warranty, the product must have been properly set up and tested by a Polaris Dealer (if ap

123WARRANTYPolaris Second Year Engine Service ContractSecond Year Engine Service Contract is standard on all eligible new and unused snow-mobiles that

124WARRANTYExported VehiclesEXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOL

125WARRANTYSnowmobile Engine Emissions Limited WarrantyThis snowmobile engine emissions limited warranty is in addition to the Polaris stan-dard limit

126WARRANTYSnowmobile Engine Emissions Limited WarrantySome states do not allow limitations on how long an implied warranty lasts, so the above limita

10SAFETYOperator SafetyStay Clear of TrackYour snowmobile is propelled by a revolving track that must be partially exposed for proper operation.Stay C

127MAINTENANCE LOGPresent this section of your manual to your dealer each time your snow-mobile is serviced. This will provide you and future owners w

128MAINTENANCE LOGDATE MILES(KM)TECHNICIAN SERVICE PERFORMED / COMMENTS

129MAINTENANCE LOGDATE MILES(KM)TECHNICIAN SERVICE PERFORMED / COMMENTS

130INDEXAAccessories . . . . . . . . . . . . . . . . . . . 48Apparel for Riding. . . . . . . . . . . . . . 12Avalanches. . . . . . . . . . . . .

131INDEXLLights . . . . . . . . . . . . . . . . . . . . . . . . 95Limiter Strap Position . . . . . . . . . . . . 44Low Oil Indicator Light . . . .

132INDEXTTether Switch. . . . . . . . . . . . . . . . . . 48Throttle Lever . . . . . . . . . . . . . . 50, 64Throttle Safety Switch . . . . . . .

11SAFETYOperator SafetyRiding PositionOperating a snowmobile requires skill and balance for proper control. Rider positions may vary with experience;

12SAFETYOperator SafetyRiding ApparelHelmetWearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet

13SAFETYOperator SafetyDisabled OperatorsSafe operation of this rider-active vehicle requires good judgement and physical skills.Rider CapacityYour Po

14SAFETYOperator SafetyDriver AwarenessSlow down when traveling near poles, posts, or other obstacles. Be especially alert if you’re snowmobiling afte

15SAFETYOperator SafetyAvalanchesSnowmobilers should always be properly trained and equipped before traveling in mountainous terrain:• Take an avalanc

16SAFETYOperator SafetyIce and Snow Build-upBefore driving, manually turn the skis to the left and right to be sure ice and snow are not interfering w

17SAFETYOperator SafetyDriving on Slippery SurfacesDriving in Hilly TerrainUse extra caution when operating in hilly terrain. If climbing a hill is un

18SAFETYOperator SafetyDrive BeltDo not operate the engine with the drive belt removed.Any servicing that requires operation without a belt must be pe

19SAFETYOperator SafetyInadequate Snow ConditionsSince snow provides the only lubrication for the power slide suspension and, on liquid cooled models,

20SAFETYOperator SafetyDriving ResponsiblyEvery snowmobile handles differently, and even the most docile condi-tions may become dangerous if operators

21SAFETYOperator SafetyWindchill/Temperature ChartsThe following information is provided to help you determine when tem-peratures become dangerous for

22SAFETYSafety Decals and LocationsWarning decals have been placed on the snowmobile for your protec-tion. Read and follow the instructions of the dec

23SAFETYSafety Decals and Locations“No Passenger” WarningSnowmobiles designed for only a single rider have a warning decal on the console below the st

24SAFETYSafety Decals and LocationsReverse WarningPolaris snowmobiles equipped with electric reverse have a reverse warning decal on the console.WARNI

25SAFETYSafety Decals and LocationsOperation Warning(continued from previous page)• Excessive speed, especially at night or with limited visibility, c

26FEATURES1. Front Bumper2. Hood3. Headlight4. Windshield5. Mountain Bar (if equipped)6. Handlebar7. Seat8. Taillights9. Rear Bumper10. Snow Flap11. T

WARNINGRead, understand, and follow all of the instructions and safety precautions in this manual and on all product labels.Failure to follow the safe

27FEATURES1. Fuel Filler Cap2. Ignition Switch3. MFD (Multi-Function Display)4. Engine Stop Switch5. Throttle Control6. Recoil Starter Handle7. Hood H

28FEATURESAccessory Cargo SystemThe maximum weight capacity for the rear cargo area is 15 lbs. (7 kg). Always secure cargo before operating. Do not ex

29FEATURESDetonation Elimination Technology (DET)A detonation sensor monitors the engine and responds to detonation by automatically reducing the engi

30FEATURESInstrumentationMFD Component IdentificationItem1 Analog Gauge (if equipped)2 Digital Gauge3 Check Engine Indicator4 Low Oil Indicator5 High

31FEATURESInstrumentationDigital Display IdentificationItem1 RPM or SpeedAltitude (if equipped)Service Interval2 Electrical System Voltage Level3 MAX

32FEATURESInstrumentationMFD SettingsThe MFD Control Switch allows you to set the MFD display to your preferences. The rocker switch has a MODE button

33FEATURESInstrumentationMFD Digital Display ProgramsPress and release the MODE button to cycle through the three MFD pro-grams: Performance, Engine a

34FEATURESInstrumentationMFD Digital Display ProgramsPerformance ProgramTrip SettingsTrip F automatically displays when the fuel level is low if the s

35FEATURESInstrumentationMFD Digital Display ProgramsEngine ProgramAir Temperature (accessory)The MFD displays actual air temperature. Press and hold

36FEATURESInstrumentationMFD Digital Display ProgramsHistory ProgramPress and release the MODE button until the history program screen is active. This

1WELCOMEThank you for purchasing a Polaris vehicle, and welcome to our world-wide family of Polaris owners. We proudly produce an exciting line of uti

37FEATURESInstrumentationMFD Digital Display ProgramsHistory ProgramService Interval ReminderThe gauge logs the number of engine hours accumulated bet

38FEATURESInstrumentationGauge Cleaning1. Wipe the gauge face as needed using a clean cloth and a mild soap and water solution. Wipe dry with clean, s

39THE PERFECT FITIQ Front Suspension AdjustmentsIndependent Front Suspension (IFS)Break in the suspension for approximately 150 miles (240 km) before

40THE PERFECT FITIQ Front Suspension AdjustmentsAir ShocksWalker Evans air shocks can be adjusted for preload and valving. Please see your Polaris dea

41THE PERFECT FITIQ Front Suspension AdjustmentsFront Shock Spring Preload(RMK Premium Only)Increasing spring preload will increase ski-to-ground pres

42THE PERFECT FITRear Suspension AdjustmentsRider weight, riding style, trail conditions, and vehicle speed all affect suspension action.Each rear sus

43THE PERFECT FITRear Suspension AdjustmentsInitial Spring Preload Setting (Sag Method)To set up the rear suspension torsion spring preload, measure t

44THE PERFECT FITRear Suspension AdjustmentsTorsion Spring PreloadTo adjust rear torsion spring preload, rotate the three-position cam using the engin

45THE PERFECT FITRear Suspension AdjustmentsShock Compression ValvingRMK Standard Rear Track ShockThe standard RMK rear track shock is an Arvin MPV Se

46THE PERFECT FITHandlebar AdjustmentsHandlebar position and handlebar angle can be adjusted to rider prefer-ence. After making handlebar adjustments,

2POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus-tries Inc.Copyright 2006 Polaris Sales Inc. All information contained with

47THE PERFECT FITHandlebar AdjustmentsHandlebar Position1. Loosen the four bolts on the bottom of the adjuster block. NOTE: If necessary, pry the bloc

48THE PERFECT FITAccessoriesPolaris offers a wide range of accessories for your snowmobile to help make each ride more enjoyable.Use only Polaris part

49PRE-RIDE INSPECTIONSPre-Ride ChecklistInspect all items on the checklist for proper operation or condition before each use of the snowmobile. Proced

50PRE-RIDE INSPECTIONSCheck Before Starting the EngineRead and Understand Your Owner's ManualRead the Owner's Manual completely and refer to

51PRE-RIDE INSPECTIONSCheck Before Starting the Enginen Recoil RopeInspect the recoil rope and handle for excessive wear, and make sure the knot secur

52PRE-RIDE INSPECTIONSCheck Before Starting the Enginen Parking Brake Lever LockUse the parking brake lever lock only when you want the snowmobile to

53PRE-RIDE INSPECTIONSCheck Before Starting the Enginen Steering SystemManually turn the skis completely to the right and to the left. If any dif-ficu

54PRE-RIDE INSPECTIONSCheck Before Starting the Enginen Suspension InspectionLoose nuts and bolts can reduce your snowmobile's reliability and ca

55PRE-RIDE INSPECTIONSCheck After Starting the Enginen Engine Stop SwitchCheck the auxiliary shut-off switch for proper operation. Push the switch dow

56OPERATIONStarting the EngineDo not depress the throttle until the engine starts.1. Turn the key to the ON position.2. Pull the engine stop switch up

3TABLE OF CONTENTSIntroduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5This section contains helpful information for owners and dri

57OPERATIONEngine Break-InNo single action on your part is as important to long, trouble-free machine life as proper break-in of a new or rebuilt engi

58OPERATIONEngine Break-InOil Injection SystemAlways fill the oil reservoir when refueling.Oil RecommendationsThis snowmobile is equipped with a varia

59OPERATIONTrack Warm-UpFollow these steps to ensure proper warm-up of the engine, drive train and track.1. Use an appropriate stand to securely suppo

60OPERATIONFuel SafetyWARNINGGasoline is highly flammable and explosive under certain conditions.• Always exercise extreme caution whenever handling g

61OPERATIONFuelFor peak performance, Polaris recommends the use of 91 octane or higher fuel. Although 87 octane fuel is usable, some engine perfor-man

62OPERATIONOiln Low Oil Indicator LightThe low oil indicator light will alert the operator if the oil level is low. Visually check for oil in the bott

63OPERATIONn Engine Stop SwitchPush down on the engine stop switch to ground out the ignition and stop the engine quickly. Pull the switch up to the R

64OPERATIONn Throttle LeverIf the engine stops abruptly when the throttle lever is released:1. Turn the ignition switch to OFF.2. Visually inspect the

65OPERATIONn Emergency StoppingThe following chart lists methods for stopping the snowmobile in the event of an emergency. See page 63 for more inform

66OPERATIONEmergency StartingIf the recoil starter system fails, an emergency start strap is provided in the tool kit.1. Open the hood.2. Remove the l

4

67OPERATIONElectronic Reverse (PERCt)Electronic reverse will activate only if the engine RPM is below 4000. The maximum engine RPM will be 6000 when i

68OPERATIONDaily StorageAt the end of each ride, park the snowmobile on a level surface and support it at the rear with an appropriate track stand. Th

69MAINTENANCEEmission Control InformationAny qualified repair shop or qualified person may maintain, replace, or repair the emission control devices o

70MAINTENANCEEmission Control InformationOwner's ResponsibilitiesPlease read the Snowmobile Engine Emissions Limited Warranty on page 125, and re

71MAINTENANCEPolaris Recommended Maintenance ProgramTo ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenanc

72MAINTENANCEPeriodic Maintenance Interval TableThe following chart is a guide based on average riding conditions. You may need to increase frequency

73MAINTENANCEPeriodic Maintenance Interval TableItem See PageFrequency150 mi.(240 km)500 mi.(800 km)1000 mi.(1600 km)2000 mi.(3200 km)Pre-SeasonBRAKES

74MAINTENANCEPeriodic Maintenance Interval TableI - Inspect (clean, adjust, tighten, lubricate, replace if necessary)C - Clean R - Replace L - Lubrica

75MAINTENANCELubricationFront SuspensionThe front suspension does not require lubrication.Rear SuspensionLubricate the suspension pivot shafts with Po

76MAINTENANCELubricationDriveshaft BearingInject grease into the fitting on the speed-ometer sensor housing until grease purges from the seal on the i

5INTRODUCTIONImportant Notes for Owners and DriversAfter reading this manual, store it in the snowmobile for convenient ref-erence. It should remain w

77MAINTENANCELubricationn Chaincase OilCheck the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 71. The sig

78MAINTENANCELubricationChaincase OilOil Change 1. Position the vehicle on a level surface.2. Remove the drain plug and drain the oil into a drain pan

79MAINTENANCESpark PlugsSpark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine ha

80MAINTENANCESpark PlugsA new engine can cause temporary spark plug fouling due to the preser-vative added during the assembly process. Avoid prolonge

81MAINTENANCEIntake FiltersThe intake foam filter limits snow ingestion into the intake system. When operating in loose powder snow, check the top of

82MAINTENANCEFuel Injectors (DRAGON RMK)All fuel injector service must be performed by an authorized Polaris dealer. Do not attempt to clean or servic

83MAINTENANCECarburetor (600 RMK)The number stamped in the end of the main jet indicates the jet size. The jet installed at the time of manufacture is

84MAINTENANCECarburetor Water/Sediment Trap (600 RMK)Most Polaris snowmobiles contain patented carburetor bowl water/sedi-ment traps located at the bo

85MAINTENANCEExhaust SystemCheck the exhaust system for wear or damage at the intervals outlined in the Periodic Maintenance Table beginning on page 7

86MAINTENANCECooling SystemCoolantThe coolant supplied in the system is a 60/40 mixture of ethylene-glycol and distilled water. This mixture provides

6INTRODUCTIONPreservation of the EnvironmentPolaris is committed to supporting an environmental education cam-paign. We encourage state and provincial

87MAINTENANCECooling SystemCoolant High Temperature Indicator LightThe high temperature indicator light will illuminate when engine cool-ant temperatu

88MAINTENANCECooling SystemBleeding the Cooling SystemUse of a non-standard pressure cap will not allow the recovery system to function properly. If t

89MAINTENANCECooling SystemBleeding the Cooling SystemBleed the cooling system at the intervals outlined in the Periodic Main-tenance Table beginning

90MAINTENANCEDrive Chain TensionCheck drive chain tension weekly and before each long trip. To obtain correct chain tension:1. Rotate the driven clutc

91MAINTENANCEBrakesn Hydraulic Brake InspectionInspect the brake lever travel before each use of the snowmobile. See page 51.Brake pads must be replac

92MAINTENANCEBrakesBrake Components•Brake Disc• Bleed Screw•Brake Line• Brake Caliper• Brake Pad Material - Replace when thickness is less than 1/16&q

93MAINTENANCEBrakesn Brake FluidReplace brake fluid at least every two years with Polaris DOT 4 high tem-perature brake fluid. See page 112 for the pa

94MAINTENANCEBrakesBleeding the Hydraulic Brake SystemAir in the hydraulic brake system will cause spongy brake lever action. Bleed the system before

95MAINTENANCELightsRemoving Halogen BulbsNOTE: Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that

96MAINTENANCEClutch SystemPeriodically inspect clutch sheaves for damage, wear or belt residue. To maintain optimum performance, clean with non-oil ba