Polaris 2005 RMK- Manuals

5 INTRODUCTION Important Notes for Owners and Drivers n After reading this manual, store it in the snowmobile for convenient reference. It should remain with the snowmobile when sold. n The illustrations and photos used in this manual are general representations. Your model may differ. n Follow the ...

6 INTRODUCTION Preservation of the Environment Polaris is committed to supporting an environmental education campaign. We encourage state and provincial governments across the snowbelt to adopt rigorous safety training programs that encourage protection of our environment, including wildlife and veg...

7 INTRODUCTION Vehicle Identification Numbers The tunnel vehicle identification number (VIN) and engine serial number are important for model identification when registering your snowmobile, when obtaining insurance, and when ordering replacement parts. In the event your snowmobile is stolen, these ...

8 SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol , on your vehicle or in this manual...

9 SAFETY Operator Safety Your Polaris snowmobile is a well-engineered and well-constructed recreational vehicle. Follow the recommended maintenance program outlined beginning on page 64 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at...

10 SAFETY Operator Safety Stay Away From Moving Parts WARNING Never hold the snowmobile up or stand behind it while warming up the track. A loose track or flying debris could cause serious personal injury or death.We recommend having your dealer perform track service and alignment procedures. Be ale...

11 SAFETY 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 th...

12 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 vehicl...

13 SAFETY Operator Safety Driver Awareness Slow down when traveling near poles, posts, or other obstacles. Be especially alert if you’re snowmobiling after dark. Always be on the alert for wire fences. Single strands are especially dangerous, since there may be a great distance between posts. Guy wi...

14 SAFETY Operator Safety Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain: S Take an avalanche class S Travel with experienced people S Travel on designated trails S Make sure each person is equipped with a shovel, probe and avalanche be...

15 SAFETY Operator Safety Ice and Snow Build-up WARNING Ice and snow build-up may interfere with the steering of your machine, resulting in serious injury or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are ...

16 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 c...

17 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...

18 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 clutc...

19 SAFETY Operator Safety Powder Snow Operation Moveable hood closures are included on some Polaris snowmobiles. They are normally left open and are located on the front upper and lower hood openings. If operating in deep snow or in extreme cold conditions (below -20 _ F), Polaris recommends closing...

20 SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently, and even the most docile conditions may become dangerous if operators drive improperly. If you’re new to snowmobiling, acquaint yourself with the machine and with what it will and won’t do under various conditions. E...

21 SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding.WIND CHILL CHART ( ° F) Estimated Wind Speed in MPH Actual Thermometer Reading ( ° F) Speed in MPH 50 40 30 20 10 0 -10 -20 -30 -40 -50 -60...

22 SAFETY Safety Decals and Locations Warning decals have been placed on the snowmobile for your protection. Read and follow the instructions of the decals and other warnings on the snowmobile carefully. If any of the decals depicted in this manual differ from the decals on your snowmobile, always r...

23 SAFETY Safety Decals and Locations Track/Seat Warning The track/seat warning decal is on the rear of the tunnel: Stay clear of track. Do not sit on seat back. Entanglement with the track or a fall from seat back may result in severe injury or death. Reverse Warning Some Polaris snowmobiles are eq...

24 SAFETY Safety Decals and Locations Operation Warning An operation warning decal is present on the console of all Polaris snowmobiles: S To avoid serious injury or death, read and understand all warnings and the Owner’s Manual before operation. If manual is missing, contact a Polaris dealer for a ...

25 FEATURES AND CONTROLS Controls 1. Fuel Filler Cap (may include a fuel gauge) 2. Ignition Switch 3. Brake Lever 4. Speedometer (may include indicator/warning lights) 5. Tachometer (may include indicator/warning lights) 6. Engine Stop Switch (see page 58) 7. Throttle Control 8. Recoil Starter Handl...

26 FEATURES AND CONTROLS Controls Some Polaris snowmobiles are equipped with special features. Controls for these features are illustrated on this page. Not all models come with these features. Refer to your Owner’s Manual Supplement for a list of features on your machine.Accessories are available f...

27 FEATURES AND CONTROLS Features 1. Hood 2. Headlight 3. Windshield 4. Handlebar 5. Seat 6. Storage Compartment 7. Taillights 8. Snow Flap 9. Track 10. Suspension 11. Trailing Arm 12. Nosepan 13. Front Bumper 14. Skis 8 4 3 2 1 13 5 7 9 10 12 11 14 6

29 THE PERFECT FIT Front Suspension Adjustments Break in the suspension for approximately 150 miles (240 km) and re-grease all suspension parts before fine-tuning adjustments are made.Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions...

30 THE PERFECT FIT Front Suspension Adjustments WARNING Always verify ski alignment before making adjustments to the IFS. See page 102 to check alignment. If the skis are misaligned, see your dealer, as the camber adjustment may also be affected. The tension at which the shock coil spring is set is ...

31 THE PERFECT FIT Front Suspension Adjustments Shock Damping Adjustments to the compression stiffness of Indy Select or RydeFX SOLO shocks can be made by turning the adjustment screw (Select) or actuator (SOLO), located near the base of the shock (A). This adjustment is the easiest to perform and i...

32 THE PERFECT FIT Front Suspension Adjustments Adjusting Front 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...

33 THE PERFECT FIT Front Suspension Adjustments Shock Valving RydeFX or RydeFX SOLO shocks can be revalved if spring preload alone isn’t sufficient and further adjustment is desired to control suspension stiffness. WARNING Changing shock valving on RydeFX and RydeFX SOLO shocks requires special tool...

34 THE PERFECT FIT Rear Suspension Adjustments Suspension Set-Up Rider weight, riding style, trail conditions, and vehicle speed all affect suspension action. Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. However, all s...

35 THE PERFECT FIT Rear Suspension Adjustments Indy Select Rear Shock Some snowmobiles are equipped with the Indy Select rear shock, which allows for adjustments to the compression valving by turning the adjustment screw located near the base of the shock. Adjustment Locate the adjustment screw (A) ...

36 THE PERFECT FIT Handlebar Adjustments Standard Handlebar Follow these steps to adjust the handlebar for a personal fit.1. Remove the handlebar cover to access the four adjuster block bolts (A). 2. Using a 7/16 ″ (11 mm) wrench, loosen the four nuts on the bottom of the adjuster block (turn the ha...

37 THE PERFECT FIT Handlebar Adjustments Handlebar Hooks Anytime the handlebar hooks (A) are removed for service, make sure they’re reinstalled properly before operating the snowmobile. Torque the bolts (B) to 12 ft. lbs. (16 Nm). Accessories Polaris offers a wide range of accessories for your snowm...

38 THE PERFECT FIT Accessories 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. CAUTION Insta...

39 THE PERFECT FIT Accessories Traction Products A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain. The addition of carbide skags is recommended with studded tracks to help ...

40 THE PERFECT FIT Accessories 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 ac...

42 PRE-RIDE INSPECTIONS Before Starting the Engine WARNING Worn, damaged, or malfunctioning components may cause serious injury or death. Before starting the engine, check all components to be sure of proper operation. Read and Understand Your Owner’s Manual Read the Owner’s Manual completely and re...

43 PRE-RIDE INSPECTIONS Before Starting the Engine n Hydraulic 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 When the brake lever is squeezed, it should move no closer to the ...

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

45 PRE-RIDE INSPECTIONS Before Starting the Engine n Check for Proper Operation of Steering System Manually turn the skis completely to the right and to the left. If any difficulty is encountered, check for ice and snow build-up that may be obstructing the steering linkage. Make sure all greasable c...

46 PRE-RIDE INSPECTIONS Start the Engine and Check n Transmission: Make sure the reverse is not engaged before starting your machine. n Engine Stop Switch: Check the auxiliary shut-off switch for proper operation. Push down to stop the engine. Pull up to release and start the engine. n Tether Switch...

47 OPERATION Starting the Engine WARNING Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start your snowmobile without checking all components to be sure of proper operation. See Check Before Starting the Engine beginning on page 42. Starting...

48 OPERATION Starting the Engine Starting a Cold Engine (Electric Start) Do not depress the throttle until the engine starts.1. Flip choke toggle to FULL ON. 2. Pull kill switch (shut-off switch) up to RUN . 3. Turn key to START and crank engine. 4. After the engine starts, release the key to ON and...

49 OPERATION Engine Break-In No single action on your part is as important to long, trouble-free machine life as proper break-in of a new or rebuilt engine. 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 su...

50 OPERATION Engine Break-In Oil Injection System CAUTION Serious engine damage can occur without the proper lubrication. Check the oil tank level often during the first tankful of fuel. If the oil level doesn’t go down, contact your dealer immediately. Always fill the oil reservoir when refueling. ...

52 OPERATION Slide Rail and Track Cooling CAUTION 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 s...

53 OPERATION Fuel The fuel used in your Polaris engine is as important to engine life and performance as the lubricant used.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 ga...

54 OPERATION Fuel Premium Fuel Switch If you’re uncertain about the quality or octane rating of the fuel you use, turn your key switch to ON/REG. The Premium Fuel light will go out. This setting will adjust the timing of your engine to run on fuels with 87 octane or higher. Polaris does not recommen...

55 OPERATION Oil n Low Oil Indicator Light The low oil indicator light will indicate when to add oil. See page 50 for oil recommendations.When the low oil indicator light is on, oil should be added before further operation of the snowmobile. Visually check the oil level in the bottle. The engine may...

56 OPERATION Oil n Low Oil Level Always do a visual check of the oil level when refueling. When the oil reaches the low level mark, add one U.S. quart of recommended oil to the tank. See page 50 for oil recommendations.The Polaris oil cap on the oil tank may be vented to allow proper oil flow. See y...

57 OPERATION 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.Carburetor...

58 OPERATION n Engine Stop Switch Push down on the engine stop switch (A) 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. n Throttle Safety Switch Test the throttle saf...

59 OPERATION Throttle Lever WARNING An improperly functioning throttle lever may cause erratic machine behavior and loss of control, which could result in serious injury or death. If the throttle lever does not work properly, DO NOT start the engine. If the engine stops abruptly when the throttle le...

60 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 WHAT IT DOES THROTTLE CONDITION Ignition Switch Interrupts ignition circui...

61 OPERATION Emergency Starting Your machine is equipped with a tool kit containing essential tools for emergency use. Machines equipped with electric start have a recoil for emergency starting. On manual start models, an emergency start strap is provided for use if the recoil starter system fails. ...

62 OPERATION Reverse Operation Electronic Reverse (PERC t ) 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 ignition setting as described below. Always make sure the vehicle is stopped and the engine is ru...

63 OPERATION Daily Storage At the end of each ride, park the snowmobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4 ″ (20 cm) off the ground.Remove the key and cover the machine. NOTE: Polaris has accessory covers and t...

64 MAINTENANCE Polaris Recommended Maintenance Program To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and service checks outlined in this manual.The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections ...

65 MAINTENANCE Periodic Maintenance Interval Table 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 d...

69 MAINTENANCE Maintenance Log Present this section of your manual to your dealer each time your snowmobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. 150 Mile (240 km) Initial Maintenance Inspection Authorized P...

70 MAINTENANCE Maintenance Log Additional Services Performed Authorized Polaris Servicing DealerServicing TechnicianDate Mileage Type of Service Additional Services Performed Authorized Polaris Servicing DealerServicing TechnicianDate Mileage Type of Service

71 MAINTENANCE Lubrication Lubricate the suspension and steering components with Polaris Premium All-Season Grease at 500 miles (800 km) and annually or every 1000 miles (1600 km) thereafter. See page 112 for the part numbers of Polaris products.The illustration shows the location of suspension and ...

72 MAINTENANCE Lubrication 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 ...

73 MAINTENANCE Lubrication Jackshaft Bearing Greasing Loosen the driven clutch retaining bolt and pull the clutch outward to expose the bearing and grease fitting. Inject grease into the grease fitting in the flangette until grease purges from inside or outside the bearing seal (may take only two pu...

74 MAINTENANCE Lubrication n Chaincase Oil Level It’s the operator’s responsibility to check and maintain the proper chaincase oil level.To check the oil level, place the machine on a level surface. The oil level should be between the “safe” marks on the dipstick (A). Add Polaris synthetic chaincase...

75 MAINTENANCE General 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.In selecting a spark plug...

76 MAINTENANCE General Maintenance 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. WARNING ...

77 MAINTENANCE General Maintenance Intake Filter The intake foam filter limits snow ingestion into the intake system. When operating in loose powder snow, check the top of the foam filter periodically to remove any accumulation of snow. CAUTION Operating the snowmobile with the intake filters remove...

78 MAINTENANCE General Maintenance Variable Exhaust System (V.E.S.) Maintenance of the V.E.S. is limited to a periodic inspection and cleaning of system components. Every 1000 to 2000 miles, bring the machine to an authorized Polaris dealer to have the V.E.S. disassembled, inspected, and cleaned. NO...

79 MAINTENANCE General Maintenance Water/Sediment Trap Service Most Polaris snowmobiles contain patented carburetor bowl water/sediment 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 con...

80 MAINTENANCE General Maintenance Fuel Filter/Fuel Lines See your Polaris dealer for replacement of the in-tank fuel filter (1) every 1000 miles (or annually).Inspect the fuel lines regularly for signs of deterioration or damage. Always check fuel line condition after periods of storage. Normal det...

81 MAINTENANCE General Maintenance General Carburetor Information The number stamped in the end of the main jet indicates the jet size. The jet installed at the time of manufacture is not necessarily correct for your elevation. It’s your dealer’s responsibility to make sure the correct main jet is i...

82 MAINTENANCE General 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 ret...

83 MAINTENANCE General Maintenance Engine Cooling - Liquid Cooled Models Coolant High Temperature Indicator Light The high temperature indicator light is controlled by a switch in the engine cooling system on liquid cooled models. If the engine coolant reaches a certain temperature, the switch compl...

84 MAINTENANCE General Maintenance Engine Cooling - Liquid Cooled Models Bleeding the Cooling System If the pressure cap needs replacement, contact your dealer for the correct part. Use of a non-standard pressure cap will not allow the cooling system to function properly. WARNING Steam and hot liqui...

85 MAINTENANCE General Maintenance Drive Chain Tension To obtain correct chain tension:1. Rotate the driven clutch counterclockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly. 2. Loosen the adjuster bolt jam nut (A). 3. ...

86 MAINTENANCE General Maintenance n Hydraulic Brake Inspection Frequently inspect the brake lever reserve. Firmly depress the brake lever and measure the clearance between the lever and handlebar grip. This distance, called brake lever reserve (A), should be no less than 1/2 ″ (1.3 cm). Brake pads ...

87 MAINTENANCE General Maintenance Brake Components Air cooled model Liquid cooled model 1. Brake Caliper 2. Chaincase 3. Brake Disc 4. Backing Plate 5. Brake Pad Material (Replace when thickness is less than 1/16 ″ ). Excessive Lever Travel Hydraulic brakes are self-adjusting, but if excessive brak...

88 MAINTENANCE General Maintenance Brake Fluid WARNING After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake...

89 MAINTENANCE General Maintenance 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 ...

90 MAINTENANCE General Maintenance Headlight Adjustment The headlight may be adjusted for vertical aim using the following procedure:1. Place the snowmobile on a level surface with the headlight approximately 25 feet (7.6 m) from a wall. 2. Measure the distance from the floor to the center of the he...

91 MAINTENANCE General Maintenance NOTE: 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. Removing Halogen Bulbs 1. Pinch the ends of the spring (1) together and lift until it releases from the spring retainer...

92 MAINTENANCE General Maintenance Clutch System WARNING If you become aware of higher than normal clutch engagement or an unusual vibration or shift pattern, see your dealer immediately. Do not operate the machine until repairs have been made.All clutch maintenance and repairs must be performed by ...

93 MAINTENANCE General Maintenance n Drive Belt Condition Periodically check the condition and tension of the drive belt, and always carry a spare. Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions ex...

94 MAINTENANCE General Maintenance Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack (A). NOTE: 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 ...

95 MAINTENANCE General Maintenance 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 (A) and apply downward pressure while measuring at point B. This measurement should be 1 1/4”. Drive Belt Adjustment TEAM...

96 MAINTENANCE General Maintenance Torque Stop Your snowmobile is equipped with an engine torque stop (1). Periodically check the torque stop clearance. With clutches in proper alignment, the torque stop clearance should be a minimum of .010 ″ to a maximum of .030 ″ from the engine case (2). Adjust ...

97 MAINTENANCE General Maintenance For Your Protection For added protection, carry the following items on your snowmobile at all times: S Spare Drive Belt S Spare Set of Spark Plugs S Extra Oil S Extra gasoline S Fuel Deicer S Tow Rope S Trail Map S First Aid Kit S Winter Survival Kit S Avalanche Be...

98 MAINTENANCE Track Maintenance Track Inspection WARNING Broken track rods are a serious safety hazard. They 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. Using a hoist, sa...

99 MAINTENANCE Track Maintenance WARNING Moving parts can cut and crush body parts. When performing the checks and adjustments recommended on the following pages, stay clear of all moving parts. Never perform track measurement or adjustments with the engine running. Track Tension Track adjustment is...

100 MAINTENANCE Track Maintenance I f the track needs adjustment (continued): 8. Repeat measurement on the other side of the track. NOTE: Check more frequently when machine is new. 9. Start machine and slowly rotate the track at least five revolutions. Let the track come to a stop (do not apply brak...

101 MAINTENANCE Steering System Steering Inspection and Adjustment Each week, or before a long ride, check fasteners and tighten if necessary. Specific fasteners that should be checked are marked with a + in the following illustrations. EDGE IFS Steering System + + + + + + +

102 MAINTENANCE Steering System 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 posit...

103 MAINTENANCE Steering System n Ski Skags WARNING Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causing serious injury or death.See your dealer’s studding chart for recommended skags. If you install longer or more aggressive carbide skags than the origi...

104 MAINTENANCE Suspension Maintenance n Hi-Fax Wear Check Hi-fax wear by measuring the thickness at several points along the rail (A). Replace Hi-fax when a thickness of 7/16 ″ is reached. Take the machine to your dealer for Hi-fax replacement.If excessive Hi-fax wear occurs due to poor snow condit...

106 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 pl...

107 MAINTENANCE Extended Storage Controls and Linkage All bushings, spindle shafts, tie rod ends, and cables should receive a light coat of oil or grease. Bearings Grease the jackshaft and drive shaft clutch side bearings with Polaris Premium All-Season Grease or a similar high quality grease to pre...

108 MAINTENANCE Extended Storage 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 112 for the part numbers of Polaris products.Replace worn or frayed electrical...

109 MAINTENANCE Battery Battery Fluid 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 medical attention.KEEP OUT OF REACH OF CHILDREN.EXTERNAL: Flush with water.INTERNAL: Drink large...

110 MAINTENANCE Battery Battery Connections Keep battery terminals and connections free of corrosion. When cleaning is necessary, remove the corrosion with a stiff wire brush. Wash terminals and connections with a solution of one tablespoon baking soda and one cup water. Rinse well with tap water an...

111 MAINTENANCE Battery Installation WARNING Batteries contain gases that can explode. If the battery vent tube is pinched or kinked, battery gases could accumulate. Whenever removing or installing the battery, disconnect the negative (black) cable first and reinstall the negative cable last to avoi...

112 POLARIS PRODUCTS Part No. Description Engine Lubricants 2870791 Fogging Oil (12 oz. Aerosol) 2871098 Premium 2-Cycle Engine Oil (qt.) 2871097 Premium 2-Cycle Engine Oil (gal.) 2871240 Premium 2-Cycle Engine Oil (2.5 gal.) 2871721 Premium Gold Synthetic 2-Cycle Engine Oil (qt.) 2871722 Premium Go...

113 SUSPENSION TROUBLESHOOTING Problem Solution (perform only one change at a time) Rear suspension bottoms too easily - Verify sag dimension (see set-up decal or page 114). Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions. - Increase shock compressi...

114 SUSPENSION TROUBLESHOOTING Rear Suspension Set-Up This chart is only a guideline to be used for initial suspension set-up. Your set-up may vary based on your desired riding style. Setting Initial Torsion Spring Preload (Sag Method) To set up the EDGE RMK rear suspension torsion spring preload, m...

115 TROUBLESHOOTING Belt Wear/Burn Troubleshooting Belt Wear/Burn Diagnosis Causes Solutions Driving at low RPM Drive at higher RPMs. Gear the machine down. Check beltdeflection. Insufficient warm-up Warm the engine at least five minutes. Take the drive belt offthe machine in extremely cold weather ...

116 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 Solution Erratic engine operating RPM during accelera- tion or load variations Drive clutch binding Driven clutc...

119 WARRANTY Service And Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the Polaris warranty information contained in this manual. Contact your Polaris dealer for replacement parts, service or warranty. Your dealer receives frequent updates on...

120 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 ...

122 WARRANTY Conditions and Exclusions 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 c...

123 WARRANTY Polaris Second Year Engine Service Contract Second Year Engine Service Contract is standard on all eligible new and unused snowmobiles that were Snow Checked through an authorized Polaris dealer during the March/April Snow Check promotion. The free Second Year Engine Service Contract is...

124 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR- RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that have received authorization for e...

125 INDEX A Accessories 37-40 . . . . . . . . . . . . . . . . . . Airbox 22 . . . . . . . . . . . . . . . . . . . . . . . Avalanches 14 . . . . . . . . . . . . . . . . . . . . B Battery 108-110 . . . . . . . . . . . . . . . . . . . Battery Connections 110 . . . . . . . . . . . . Battery Fluid 109 . ...