Polaris 2005 RMK User Manual

7INTRODUCTIONVehicle Identification NumbersThe tunnel vehicle identification number (VIN) and engine serialnumber are important for model identificati

97MAINTENANCEGeneral MaintenanceFor Your ProtectionFor added protection, carry the following items on your snowmobile atall times:S Spare Drive BeltS

98MAINTENANCETrack MaintenanceTrack InspectionWARNINGBroken track rods are a serious safety hazard. They can cause arotating track to come off the mac

99MAINTENANCETrack MaintenanceWARNINGMoving parts can cut and crush body parts. When performing thechecks and adjustments recommended on the following

100MAINTENANCETrack MaintenanceIf the track needs adjustment (continued):8. Repeat measurement on the other side of the track.NOTE: Check more frequen

101MAINTENANCESteering SystemSteering Inspection and AdjustmentEach week, or before a long ride, check fasteners and tighten ifnecessary. S pecific fa

102MAINTENANCESteering SystemSki AlignmentWARNINGImproper ski alignment or adjustment may cause loss of steeringcontrol, resulting in serious injury o

103MAINTENANCESteering SystemnSki SkagsWARNINGWorn skis and/or skags will adversely affect handling. Loss ofvehicle control may result, causing seriou

104MAINTENANCESuspension Maintenancen Hi-Fax WearCheck Hi-fax wear bymeasuring the thickness atseveral points along therail (A). Replace Hi-faxwhen a

105MAINTENANCESuspension MaintenanceLoose nuts and bolts can reduce your snowmobile’s reliability andcause needless repairs and down time. Before begi

106MAINTENANCEExtended StorageOff-season or extended storage of your snowmobile requires preventivemeasures to aid against deterioration and to prolon

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

107MAINTENANCEExtended StorageControls and Lin kag eAll bushings, spindle shafts, tie rod ends, and cables should receive alight coat of oil or grease

108MAINTENANCEExtended StorageElectrical ConnectionsSeparate electrical connector blocks and clean corrosive build-up fromconnectors. Lubricate or pac

109MAINTENANCEBatteryBattery FluidWARNINGBattery electrolyte is poisonous. It contains acid! Serious burnscan result from contact with the skin, eyes,

110MAINTENANCEBatteryBattery ConnectionsKeep battery terminals and connections free of corrosion. Whencleaning is necessary, remove the corrosion with

111MAINTENANCEBattery InstallationWARNINGBatteries contain gases that can explode. If the battery vent tubeis pinched or kinked, battery gases could a

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

113SUSPENSION TROUBLESHOOTINGProblem Solution (perform only one change at a time)Rear suspensionbottoms too easily- Verify sag dimension (see set-up d

114SUSPENSION TROUBLESHOOTINGRear Suspension Set-UpThis chart is only a guideline to be used for initial suspension set-up. Your set-up may varybased

115TROUBLESHOOTINGBelt Wear/Burn TroubleshootingBelt Wear/Burn DiagnosisCauses SolutionsDriving at low RPM Drive at higher RPMs. Gear the mach ine dow

116TROUBLESHOOTINGEngine TroubleshootingCAUTION: Unless you have experience and training in two-cycleengine repair, see your dealer if technical probl

9SAFETYOperator SafetyYour Polaris snowmobile is a well-engineered and well-constructedrecreational vehicle. Follow the recommended maintenance progra

117TROUBLESHOOTINGEngine TroubleshootingProblem Probable Cause SolutionNoise in drivesystemBroken drive clutchcomponentsBearing failure/chaincase, jac

118TROUBLESHOOTINGEngine TroubleshootingProblem Probable Cause SolutionEngine turnsbut fails to startFaulty ignitionNo fuel to engineFlooded engine(no

119WARRANTYService And Warranty InformationObtaining Service and Warranty AssistanceRead and understand the service data and the Polaris warrantyinfor

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 IM-PLIED WARRANTIES OF MERCHANTABILITY AND F

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

123WARRANTYPolaris Second Year Engine Service ContractSecond Year Engine Service Contract is standard on all eligible new and unusedsnowmobiles that w

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

125INDEXAAccessories 37-40...Airbox 22...Avalanches 14...BBattery 108-110...Batter

126INDEXHHalogen Bulbs 91...Handlebar Adjustments 36-37...Handlebar Hooks 37...Handlebar with Riser Block 36...Han

10SAFETYOperator SafetyStay Away From Movin g PartsWARNINGNever hold the snowmobile up or standbehind it while warming up the track. Aloose track or f

127INDEXSSuspension Maintenance 104-105...Suspension Performance Tips 34...Suspension Set-Up 34...SUSPENSIONTROUBLESHOOTING 113-114..

11SAFETYOperator SafetySurvival PreparationFor your safety, always ride i n a group of other snowmobilers. Alwaystell someone where you’re going and h

12SAFETYOperator SafetyCargo OverloadToo much weight on the rear of the machine may reduce your ability tosteer. Do not exceed carrier and rack weight

13SAFETYOperator SafetyDriver AwarenessSlow down when traveling near poles,posts, or other obstacles. Be especiallyalert if you’re snowmobiling after

14SAFETYOperator SafetyAvalanch esSnowmobilers should always be properlytrained and equipped before traveling inmountainous terrain:S Take an avalanch

15SAFETYOperator SafetyIce and Snow Build-upWARNINGIce and snow build-up may interfere with the steering of yourmachine, resulting in serious injury o

16SAFETYOperator SafetyDriving in Hilly TerrainWARNINGClimbing a hill or crossing the face of a slope may result in loss ofbalance and machine roll-ov

17SAFETYOperator SafetyDriving DownhillWhen riding downhill, shift your weight to the rear of the machine andreduce your speed to a minimum. Apply jus

18SAFETYOperator SafetyIntake SilencerDo not operate the engine with the intake silencer or filter removed.Damage to the engine may occur i f the inta

19SAFETYOperator SafetyPowder Sno w OperationMoveable hood closures are included on some P olaris snowmobiles.They are normally left open and are loca

20SAFETYOperator SafetyDriving ResponsiblyEvery snowmobile handles differently, and even the most docileconditions may become dangerous if operators d

21SAFETYOperator SafetyWindchill/Temperature ChartsThe following information is provided to help you determine whentemperatures become dangerous for r

22SAFETYSafety Decals and LocationsWarning decals have been placed on the snowmobile for yourprotection. Read and follow the instructions of the decal

23SAFETYSafety Decals and LocationsTrack/Seat WarningThe track/seat warning decal is on the rear ofthe tunnel:Stay clear of track. Do not sit on seatb

24SAFETYSafety Decals and LocationsOperation WarningAn operation warning decal is present on the console of all Polarissnowmobiles:S To avoid serious

25FEATURES AND CONTROLSControls1. Fuel Filler C ap (may include a fuel gauge)2. Ignition Switch3. Brake Lever4. Speedometer (may include indicator/war

26FEATURES AND CONTROLSControlsSome Polaris snowmobiles are equipped with special features.Controls for these features are illustrated on this page. N

WARNINGWARNINGRead, understand, and follow all of the instructionsand safety precautions in this manual and on allproduct labels.Failure to follow the

27FEATURES AND CONTROLSFeatures1. Hood2. Headlight3. Windshield4. Handlebar5. Seat6. Storage Compartment7. Taillights8. Snow Flap9. T rack10. Suspensi

28FEATURES AND CONTROLSFeaturesDetonation Elimination Technology (D.E.T.)Some Polaris snowmobiles are equipped with adetonation sensor that monitors t

29THE PERFECT FITFront Suspension AdjustmentsBreak in the suspension for approximately 150 miles (240 km) andre-grease all suspension parts before fin

30THE PERFECT FITFront Suspension AdjustmentsWARNINGAlways verify ski alignment before making adjustments to theIFS. See page 102 to check alignment.

31THE PERFECT FITFront Suspension AdjustmentsShock DampingAdjustments to the compressionstiffness of Indy Select orRydeFX SOLO shocks can bemade by tu

32THE PERFECT FITFront Suspension AdjustmentsAdjusting Front Shock Spring PreloadIncreasing spring preload will increaseski-to-ground pressure. Decrea

33THE PERFECT FITFront Suspension AdjustmentsShock ValvingRydeFX or RydeFX SOLO shocks can be revalved if spring preloadalone isn’t sufficient and fur

34THE PERFECT FITRear Suspension AdjustmentsSuspension Set-UpRider weight, riding style, t rail conditions, and vehicle speed all affectsuspension act

35THE PERFECT FITRear Suspension AdjustmentsIndy Select Rear ShockSome snowmobiles are equipped with the Indy S elect rear shock,which allows for adju

36THE PERFECT FITHandlebar AdjustmentsStandard HandlebarFollow these steps to adjust the handlebar for a personal fit.1. Remove the handlebar cover to

37THE PERFECT FITHandlebar AdjustmentsHandlebar HooksAnytime the handlebar hooks (A)are removed for service, makesure they’re reinstalled properlybefo

38THE PERFECT FITAccessoriesTraction ProductsAnother way to tailor your machine is to install traction products. S eeyour dealer about installing stud

39THE PERFECT FITAccessoriesTraction ProductsA skag is a replaceable bar attached to the underside of the ski to assistin turning the snowmobile and t

40THE PERFECT FITAccessoriesWear StripsTo avoid excessive tunnel or cooler damage, wear strips must beinstalled whenever track studding is used. See y

41PRE-RIDE INSPECTIONSPre -Ride ChecklistInspect all items on the checklist for proper operation or conditionbefore each use of the snowmobile. Proced

42PRE-RIDE INSPECTIONSBefore Starting the EngineWARNINGWorn, damaged, or malfunctioning components may causeserious injury or death. Before starting t

43PRE-RIDE INSPECTIONSBefore Starting the EnginenHydraulic BrakesProperly functioning brakesare critical to your safety.Always check the followingitem

44PRE-RIDE INSPECTIONSBefore Starting the EnginenPark Brake L ever Lo ckYour snowmobile may have a park brake lever lock located over thebrake lever.

45PRE-RIDE INSPECTIONSBefore Starting the EnginenCheck for Proper Operation of Steering SystemManually turn the skis completely to the right and to th

46PRE-RIDE INSPECTIONSStart the Engine and Checkn Transmission: Make sure the reverse is not engaged beforestarting your machine.n Engine Stop Switch:

2Copyright 2004 Polaris Sales Inc. All information contained within this publication isbased on the latest product information at the time of publicat

47OPERATIONStarting the EngineWARNINGBefore starting the engine, always refer to all safety warningspertaining to snowmobile operation. Never start yo

48OPERATIONStarting the EngineStarting a Cold Engine (Electric Start)Do not depress the throttleuntil the engine starts.1. Flip choke toggle toFULL ON

49OPERATIONEngine Break-InNo single action on your part is as important to long, trouble-freemachine life as proper break-in of a new or rebuilt engin

50OPERATIONEngine Break-InOil Injection SystemCAUTIONSerious engine damage can occur without the proper lubrication.Check the oil tank level often dur

51OPERATIONTrack Warm-UpWARNINGA loose track or flying debris could cause serious personal injuryor death. Stand clear of the front of the machine and

52OPERATIONSlide Rail and Track CoolingCAUTIONInadequate cooling and lubrication will lead to overheating of theslide rail and track, resulting in pre

53OPERATIONFuelThe fuel used i n your Polaris engine is as important to engine life andperformance as the lubricant used.Your Polaris engine is design

54OPERATIONFuelPremium Fu el SwitchIf you’re uncertain about the quality or octane rating of the fuel youuse, turn your key s witch to ON/REG. The Pre

55OPERATIONOilnLow Oil Indicator LightThe low oil indicator light will indicate when to add oil. See page 50for oil recommendations.When the low oil i

56OPERATIONOilnLow Oil LevelAlways do a visual check of the oil level whenrefueling. When the oil reaches the low levelmark, add one U.S . quart of re

3WELCOMEThank you for purchasing a P olaris vehicle, and welcome to ourworld-wide family of Polaris owners. We proudly produce an excitingline of util

57OPERATIONCarburetionJetting Gu idelinesChanges in altitude and temperature affect air density, which is theamount of oxygen available for combustion

58OPERATIONn Engine Stop SwitchPush down on the engine stopswitch (A) to stop the engine in anemergency. This will ground outthe ignition and bring t

59OPERATIONThrottle LeverWARNINGAn improperly functioning throttle lever may cause erraticmachine behavior and loss of control, which could result ins

60OPERATIONEmergency StoppingThe following chart lists methods for stopping the snowmobile in theevent of an emergency. Refer to page 58 for more info

61OPERATIONEmergency StartingYour machine is equipped with a tool kit containing essential tools foremergency use. Machines equipped with electric sta

62OPERATIONReverse OperationElectronic Reverse (PERCt)Electronic reverse will activate only if the engine is below 4000 R PM.If your machine is runnin

63OPERATIONDaily StorageAt the end of each ride, park the snowmobileon a level surface and support it at the rearwith an appropriate track stand. The

64MAINTENANCEPolaris Recommended Maintenance ProgramTo ensure many trouble-free miles of snowmobiling enjoyment, followrecommended regular maintenance

65MAINTENANCEPeriodic Maintenance Interval TableThe following chart i s a guide based on average riding conditions. Youmay need to increase frequency

66MAINTENANCEPeriodic Maintenance Interval TableSeePFrequencyItemPage150 mi.(240 km)500 mi.(800 km)1000 mi.(1600 km)2000 mi.(3200 km)Pre-SeasonBrakesH

4TABLE OF CONTENTSIntroduction 5...This section contains helpful information for owners and drivers andillustrates the loca

67MAINTENANCEPeriodic Maintenance Interval TableSeePFrequencyItemPage150 mi.(240 km)500 mi.(800 km)1000 mi.(1600 km)2000 mi.(3200 km)Pre-SeasonElectri

68MAINTENANCEPeriodic Maintenance Interval TableSeePFrequencyItemPage150 mi.(240 km)500 mi.(800 km)1000 mi.(1600 km)2000 mi.(3200 km)Pre-SeasonChassis

69MAINTENANCEMaintenance LogPresent this section of your manual to your dealer each time yoursnowmobile is serviced. This will provide you and future

70MAINTENANCEMaintenance LogAdditional Services PerformedAuthorized Polaris Servicing DealerServicing TechnicianDate MileageType of ServiceAdditional

71MAINTENANCELubricationLubricate the suspension and steering components with PolarisPremium All-Season Grease at 500 miles (800 km) andannually or ev

72MAINTENANCELubricationThe suspension pivot shafts should be l ubricated with Polaris PremiumAll Season Grease at 500 miles (800 km) initially, every

73MAINTENANCELubricationJackshaft Bearing GreasingLoosen the driven clutch retaining bolt and pullthe clutch outward to expose the bearing andgrease f

74MAINTENANCELubricationnChaincase Oil LevelIt’s the operator ’s responsibility to check and maintain the properchaincase oil level.To check the oil l

75MAINTENANCEGeneral MaintenanceSpark PlugsIt’s very important to use the correct spark plug for your machine. Aspark plug with a heat range too high

76MAINTENANCEGeneral MaintenanceSpark PlugsSpark plug condition is i ndicative of engine operation. The spark plugfiring end condition should be read

5INTRODUCTIONImportant Notes for Owners and Driversn After reading this manual, store it in t he snowmobile forconvenient reference. It should remain

77MAINTENANCEGeneral MaintenanceIntake FilterThe intake foam filter limits snow ingestion into the intake system.When operating in loose powder snow,

78MAINTENANCEGeneral MaintenanceVariable Exhaust System (V.E.S.)Mainte nanc e of the V.E.S. is limited to a periodic inspection andclea ning of system

79MAINTENANCEGeneral MaintenanceWater/Sediment Trap ServiceMost P olaris snowmobiles contain patented carburetor bowlwater/sediment traps located at t

80MAINTENANCEGeneral MaintenanceFuel Filter/Fuel LinesSee your Polaris dealer for replacement of the in-tank fuel filter (1)every 1000 miles (or annua

81MAINTENANCEGeneral MaintenanceGeneral Carburetor InformationThe number stamped in the end of the main jet indicates the jet size.The j et installed

82MAINTENANCEGeneral MaintenanceExhaust SystemCheck the exhaust system for wear or damage at approximately 1000miles (1600 km). To inspect, allow the

83MAINTENANCEGeneral MaintenanceEngine Cooling - Liquid Cooled ModelsCoolant High Temperature Indicator LightThe high temperature indicator light is c

84MAINTENANCEGeneral MaintenanceEngine Cooling - Liquid Cooled ModelsBleeding the Cooling SystemIf the pressure cap needs replacement, contact your de

85MAINTENANCEGeneral MaintenanceDrive Chain TensionTo obtain correct chain tension:1. Rotate the driven clutchcounterclockwise to move all chainslack

86MAINTENANCEGeneral MaintenancenHydraulic Brake In sp ectio nFrequently inspect the brakelever reserve. Firmlydepress the brake lever andmeasure the

6INTRODUCTIONPreservation of the EnvironmentPolaris i s committed t o supporting an environmental educationcampaign. We encourage state and provincial

87MAINTENANCEGeneral MaintenanceBrake ComponentsAir cooled model Liquid cooled model1. Brake Caliper2. Chaincase3. Brake Disc4. Backing Plate5. Brake

88MAINTENANCEGeneral MaintenanceBrake FluidWARNINGAfter opening a bottle of brake fluid, always discard any unusedportion. Never store or use a partia

89MAINTENANCEGeneral MaintenanceBleeding the Hydraulic Brake SystemAir in the hydraulic brake system will cause spongy brake lever action.Bleed the sy

90MAINTENANCEGeneral MaintenanceHeadlight AdjustmentThe headlight may be adjusted forvertical aim using the followingprocedure:1. Place the snowmobile

91MAINTENANCEGeneral MaintenanceNOTE: Avoid touching a halogen bulb with bare fingers. Oil fromskin leaves a residue, causing a hot spot that will sho

92MAINTENANCEGeneral MaintenanceClutch SystemWARNINGIf you become aware of higher than normal clutch engagement oran unusual vibration or shift patter

93MAINTENANCEGeneral MaintenancenDrive Belt ConditionPeriodically check the condition and tension of the drive belt, andalways carry a spare. Inspect

94MAINTENANCEGeneral MaintenanceDrive Belt Installation1. Drop the drive belt over thedrive clutch and pull back theslack (A).NOTE: To ensure satisfac

95MAINTENANCEGeneral MaintenancenDrive Belt DeflectionMeasure belt deflection with bothclutches at rest and in their fullneutral position.Place a stra

96MAINTENANCEGeneral MaintenanceTorque StopYour snowmobile is equippedwith an engine torque stop (1).Periodically check the torquestop clearance. With