Polaris 800 Assault RMK User Manual

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

96MAINTENANCEClutch SystemDrive Belt RemovalNOTICE: Do not attempt to remove the drive belt after operating in reverse. The snowmobile must be stopped

97MAINTENANCEClutch Systemn Drive Belt DeflectionMeasure belt deflection with both clutches at rest and in their full neutral position.Place a straigh

98MAINTENANCETrack ReplacementWhen replacing the track, always install a track having the lug size rec-ommended for your model. See your Polaris deale

99MAINTENANCETrack LubricationThe slide rail needs snow for lubrication. Excessive wear indicates insufficient lubrication. A new rail slide can cause

100MAINTENANCETrack TensionWARNING! Moving parts can cut and crush body parts. When performing the checks and adjustments recommended on the following

101MAINTENANCETrack 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

102MAINTENANCEn Track AlignmentPeriodically check that the track is centered and running evenly on the slide rails. Misalignment will cause excessive

103MAINTENANCESteering SystemSteering Inspection and AdjustmentCheck all steering system fasteners weekly and before a long ride. Tighten any loose fa

104MAINTENANCESteering SystemSki AlignmentWARNING! Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injur

105MAINTENANCESteering Systemn Ski SkagsWARNING! Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causing se

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

106MAINTENANCESteering Systemn Rail Slide WearFor ease of inspection, all Polaris rail slides have a wear limit indicator groove to indicate the minim

107MAINTENANCEMatte Clear Coat Cleaning (if equipped)Matte finish products are prone to trapping dirt, oils and other contami-nants. Polaris Industrie

108MAINTENANCEExtended StorageControls and LinkageLubricate all bushings, spindle shafts, tie rod ends and cables as outlined in the Periodic Maintena

109MAINTENANCEExtended StorageElectrical ConnectionsReplace worn or frayed electrical wire and connectors. Be sure wiring harness is properly secured

110POLARIS PRODUCTSPart No. DescriptionEngine Lubricants2870791 Fogging Oil (12 oz. Aerosol)2877882 VES Gold Plus Synthetic 2-Cycle Engine Oil (qt.)28

111TROUBLESHOOTINGEngine TroubleshootingUnless you have experience and training in two-cycle engine repair, see your dealer if technical problems aris

112TROUBLESHOOTINGEngine TroubleshootingProblem Probable Cause SolutionNoise in drive sys-temBroken drive clutch components• SEE YOUR DEALER.Bearing f

113TROUBLESHOOTINGEngine TroubleshootingProblem Probable Cause SolutionEngine turns but fails to startFaulty ignition • Install new spark plug(s). If

114TROUBLESHOOTINGSuspension TroubleshootingProblem SolutionRear suspension bot-toms too easily • Set static sag (see page 43). Adjust torsion spring

115TROUBLESHOOTINGDrive Belt TroubleshootingBelt Wear/Burn DiagnosisCauses SolutionsDriving at low RPM • Drive at higher RPM. Gear the machine down. C

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

116WARRANTYService And Warranty InformationObtaining Service and Warranty AssistanceRead and understand the service data and the Polaris warranty info

117WARRANTYService And Warranty InformationPolaris Anti-Theft SystemThe Polaris anti-theft system (PATS) monitoring program is designed to aid owners

118WARRANTYLimited WarrantyPolaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM-ITED WARRANTY on all components of the Polar

119WARRANTYLimitations of warranties and remediesALL IMPLIED WARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FI

120WARRANTYConditions and ExclusionsIn order to qualify for warranty, the product must have been properly set up and tested by a Polaris Dealer (if ap

121WARRANTYPolaris Second Year Engine Service ContractSecond Year Engine Service Contract is standard on all eligible new and unused snow-mobiles that

122WARRANTYExported VehiclesEXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOL

123WARRANTYU.S.A. EPA Emissions Limited WarrantyThis emissions limited warranty is in addition to the Polaris standard limited warranty for your vehic

124WARRANTYU.S.A. EPA Emissions Limited WarrantyThe exclusive remedy for breach of this limited warranty shall be, at the exclusive option of Polaris,

125MAINTENANCE LOGPresent this section of your manual to your dealer each time your snow-mobile is serviced. This will provide you and future owners w

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

126MAINTENANCE LOGDATE MILES(KM)TECHNICIAN SERVICE PERFORMED / COMMENTS

127MAINTENANCE LOGDATE MILES(KM)TECHNICIAN SERVICE PERFORMED / COMMENTS

128INDEXAAccessories . . . . . . . . . . . . . . . . . . . 48Apparel for Riding. . . . . . . . . . . . . . 12Avalanches. . . . . . . . . . . . .

129INDEXIIce and Snow Build-up . . . . . . . . . . . 16IFS. . . . . . . . . . . . . . . . . . . . . . . . . . . 39Instrumentation . . . . . . . . .

130INDEXSSurvival Preparation . . . . . . . . . . . . 11Suspension Adjustments, Front . . 39-41Suspension Adjustments, Rear . . 42-45Suspension

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

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.WARNING! Operators wi

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

For your nearest Polaris dealer, call 1-800-POLARISor visit www.polarisindustries.comPolaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340Phone 1-888-70

16SAFETYOperator SafetyIce and Snow Build-upWARNING! Ice and snow build-up may interfere with the steering of your snowmobile, resulting in serious in

17SAFETYOperator SafetyDriving on Slippery SurfacesWARNING! Never attempt an abrupt change of direction when operating on slippery surfaces. Proceed s

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

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

26FEATURES161. Front Bumper (do not use for pulling or dragging the snow-mobile)2. Hood3. Headlight4. Windshield5. Mountain Bar (if equipped)6. Handle

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

28FEATURESHeadlight Dimmer SwitchUse the headlight dimmer switch to adjust the headlights between high beam and low beam. Switch headlights to low bea

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

The text is printed on 100% recycled with 40% post-consumer waste (PCW).

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

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 AdjustmentsWARNING! Always verify ski alignment before making adjustments to the IFS. See page 104 to check align

41THE PERFECT FITIQ Front Suspension AdjustmentsAssault ShocksThe tension at which the shock coil spring is set is called spring preload. For the best

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 ValvingStandard Rear Track ShockThe standard RMK rear track shock is an Arvin MPV Select

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

46THE PERFECT FITHandlebar AdjustmentsWARNING! Some aftermarket accessories (including windshields and cargo bags) may interfere with the handlebar. S

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

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 INSPECTIONSBefore Starting the EngineBefore starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Ne

51PRE-RIDE INSPECTIONSBefore Starting the Enginen Recoil RopeInspect the recoil rope and handle for excessive wear, and make sure the knot securing th

52PRE-RIDE INSPECTIONSBefore Starting the Enginen Parking Brake Lever LockUse the parking brake lever lock only when you want the snow-mobile to remai

53PRE-RIDE INSPECTIONSBefore Starting the Enginen Steering SystemManually turn the skis completely to the right and to the left. If any dif-ficulty is

54PRE-RIDE INSPECTIONSBefore Starting the Enginen Suspension InspectionLoose nuts and bolts can reduce your snowmobile's reliability and cause ne

55PRE-RIDE INSPECTIONSStart the Engine and CheckBefore starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Ne

2POLARIS, THE WAY OUT, PERC, DRAGON, IQ, RMK and ASSAULT are regis-tered trademarks of Polaris Industries Inc.Copyright 2009 Polaris Sales Inc. All i

56OPERATIONStarting the EngineNOTICE: Engaging the starter when the engine is running WILL result in serious engine damage, especially if the transmis

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.NOTICE: Serious engine damage can occur without the proper

59OPERATIONTrack Warm-UpWARNING! A loose track or flying debris could cause serious injury or death. Stand clear of the front of the machine and the m

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

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 LeverWARNING! An improperly functioning throttle lever may cause erratic machine behavior and loss of control, which could resul

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

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

66OPERATIONElectronic Reverse (PERC)Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. D

67OPERATIONElectronic Reverse (PERC)Engaging Reverse1. Stop the snowmobile and leave the engine idling.2. Make sure the area behind your snowmobile is

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, and read the maint

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

4

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

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 InjectorsAll fuel injector service must be performed by an authorized Polaris dealer. Do not attempt to clean or service the fuel in

83MAINTENANCEExhaust SystemCheck the exhaust system for wear or damage at the intervals outlined in the Periodic Maintenance Table beginning on page 7

84MAINTENANCECooling SystemCoolantThe coolant supplied in the system is a 60/40 mixture of ethylene-glycol and distilled water. This mixture provides

85MAINTENANCECooling SystemCoolant High Temperature Indicator LightThe high temperature indicator light will illuminate when engine cool-ant temperatu

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

86MAINTENANCECooling SystemBleeding the Cooling SystemCAUTION! Steam and hot liquids will cause burns to your skin. Never bleed the cooling system or

87MAINTENANCECooling SystemBleeding the Cooling SystemBleed the cooling system at the intervals outlined in the Periodic Main-tenance Table beginning

88MAINTENANCEDrive Chain TensionCheck drive chain tension weekly and before each long trip. To obtain correct chain tension:1. Rotate the driven clutc

89MAINTENANCEBrakesn Hydraulic Brake InspectionInspect the brake lever travel before each use of the snowmobile. See page 51.Brake pads must be replac

90MAINTENANCEBrakesBrake Components•Brake Disc• Bleed Screw•Brake Line• Brake Caliper• Brake Pad Material - Replace when thickness is less than 1/16&q

91MAINTENANCEBrakesn Brake FluidReplace brake fluid at least every two years with Polaris DOT 4 high temperature brake fluid. See page 110 for the par

92MAINTENANCEBrakesBleeding the Hydraulic Brake SystemAir in the hydraulic brake system will cause spongy brake lever action. Bleed the system before

93MAINTENANCELightsRemoving Halogen BulbsDo not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will s

94MAINTENANCEClutch SystemPeriodically inspect clutch sheaves for damage, wear or belt residue. To maintain optimum performance, clean with non-oil ba

95MAINTENANCEClutch Systemn Drive Belt ConditionBelt width and length must match the center distance of the clutches and sheave width of the drive clu