Owners Manual
Page 5
.... Copyright 2008 Polaris Sales Inc. No liability can be accepted for reference use only. Any reprinting or reuse of the depictions and/or procedures contained within this publication. POLARIS and POLARIS THE WAY OUT...Polaris Industries Inc. All information contained within , whether whole or in part, is based on the latest product information at the time of production components, some minor discrepancies may result between the actual vehicle and the information presented in U.S.A. 2009 Owner's Manual P/N 9921613 600/800 RMK SHIFT-700/800 RMK 155-800 DRAGON RMK-800 ASSAULT RMK...
.... Copyright 2008 Polaris Sales Inc. No liability can be accepted for reference use only. Any reprinting or reuse of the depictions and/or procedures contained within this publication. POLARIS and POLARIS THE WAY OUT...Polaris Industries Inc. All information contained within , whether whole or in part, is based on the latest product information at the time of production components, some minor discrepancies may result between the actual vehicle and the information presented in U.S.A. 2009 Owner's Manual P/N 9921613 600/800 RMK SHIFT-700/800 RMK 155-800 DRAGON RMK-800 ASSAULT RMK...
Owners Manual
Page 14
... the owner's manual on your vehicle. Survival Preparation For your safety, always ride in a position that 's appropriate to the conditions you expect to : extra clothing, a sleeping bag, a flashlight, food and water, a signaling mirror, a means of Spark Plugs Tow Rope Extra Oil Fuel Deicer Winter Survival Kit Trail Map First Aid Kit Tool Kit 11 Such equipment may reduce control and could result in serious injury or death. WARNING...
... the owner's manual on your vehicle. Survival Preparation For your safety, always ride in a position that 's appropriate to the conditions you expect to : extra clothing, a sleeping bag, a flashlight, food and water, a signaling mirror, a means of Spark Plugs Tow Rope Extra Oil Fuel Deicer Winter Survival Kit Trail Map First Aid Kit Tool Kit 11 Such equipment may reduce control and could result in serious injury or death. WARNING...
Owners Manual
Page 21
... of time, especially overnight, always make sure the skis and track are removed. All clutch service must be performed by the shifting of your snowmobile has been parked for a length of the engine with the drive belt removed. Cold Weather Drive-Away Whenever your body weight. Maneuverability will change for a passenger. Intake Silencer Do not operate the engine with respect for lighter operators or snowmobiles designed to service the clutches...
... of time, especially overnight, always make sure the skis and track are removed. All clutch service must be performed by the shifting of your snowmobile has been parked for a length of the engine with the drive belt removed. Cold Weather Drive-Away Whenever your body weight. Maneuverability will change for a passenger. Intake Silencer Do not operate the engine with respect for lighter operators or snowmobiles designed to service the clutches...
Owners Manual
Page 23
...experience. • Before allowing someone else to avoid accidents. • Remove the key from the course. • Don't "jump" your vehicle. Check to oncoming traffic by dimming your headlights and reducing your speed. • When traveling in a group of their protection, as well as ...from flying snow and debris. Drive defensively to use . • Be courteous to see if they take a snowmobile safety course. Even seasoned drivers should spend some time getting the feel for proper balance in darkness or other low visibility conditions. Always start on a smooth, level area...
...experience. • Before allowing someone else to avoid accidents. • Remove the key from the course. • Don't "jump" your vehicle. Check to oncoming traffic by dimming your headlights and reducing your speed. • When traveling in a group of their protection, as well as ...from flying snow and debris. Drive defensively to use . • Be courteous to see if they take a snowmobile safety course. Even seasoned drivers should spend some time getting the feel for proper balance in darkness or other low visibility conditions. Always start on a smooth, level area...
Owners Manual
Page 28
... balance of braking ability. • Parking brake may relax when used for long periods. Check oil level when refueling. 25 Do not leave brake engaged for more than five minutes. • Before starting the engine, check throttle, brake, and steering for proper operation. Then pull the brake lever to turn or stop the engine. Safety Decals and Locations Operation Warning (continued from high speed may cause...
... balance of braking ability. • Parking brake may relax when used for long periods. Check oil level when refueling. 25 Do not leave brake engaged for more than five minutes. • Before starting the engine, check throttle, brake, and steering for proper operation. Then pull the brake lever to turn or stop the engine. Safety Decals and Locations Operation Warning (continued from high speed may cause...
Owners Manual
Page 43
... suspension should be seated at the top of the rod. Shock Rod 4. Spring (Standard only) 4 5 6 3 2 1 40 If the skis are misaligned, see your Polaris dealer for preload and valving. The bumper will be adjusted to the amount of the shocks with occasional light bottoming. If the travel that was used during the ride. THE PERFECT FIT IQ Front Suspension Adjustments WARNING...
... suspension should be seated at the top of the rod. Shock Rod 4. Spring (Standard only) 4 5 6 3 2 1 40 If the skis are misaligned, see your Polaris dealer for preload and valving. The bumper will be adjusted to the amount of the shocks with occasional light bottoming. If the travel that was used during the ride. THE PERFECT FIT IQ Front Suspension Adjustments WARNING...
Owners Manual
Page 44
... pressure. IQ Front Suspension Adjustments Front Shock Springs THE PERFECT FIT (Standard Only) The front springs can be changed if spring preload alone isn't sufficient and further adjustment is desired to adjust the shock. There are delivered in the body of the reservoir that represent the adjustment range of the vehicle. Front Shock Spring Rate (Assault Model) The Assault IFS shocks are equipped with your Polaris...
... pressure. IQ Front Suspension Adjustments Front Shock Springs THE PERFECT FIT (Standard Only) The front springs can be changed if spring preload alone isn't sufficient and further adjustment is desired to adjust the shock. There are delivered in the body of the reservoir that represent the adjustment range of the vehicle. Front Shock Spring Rate (Assault Model) The Assault IFS shocks are equipped with your Polaris...
Owners Manual
Page 67
... occurs, return the snowmobile to operate the snowmobile with the throttle safety switch disconnected. If the throttle lever operates properly, turn the ignition switch on and go through normal starting . If an emergency exists and it several times. OPERATION n Throttle Lever WARNING An improperly functioning throttle lever may cause the safety switch to activate, preventing the engine from the wire harness. DO NOT continue to an authorized...
... occurs, return the snowmobile to operate the snowmobile with the throttle safety switch disconnected. If the throttle lever operates properly, turn the ignition switch on and go through normal starting . If an emergency exists and it several times. OPERATION n Throttle Lever WARNING An improperly functioning throttle lever may cause the safety switch to activate, preventing the engine from the wire harness. DO NOT continue to an authorized...
Owners Manual
Page 68
See page 63 for stopping the snowmobile in the event of an emergency. n Emergency Stopping OPERATION The following chart lists methods for more information about the engine stop switch. SYSTEM Ignition Switch Brake Engine Stop Switch Choke (if equipped) Throttle Safety Switch Tether Switch (if equipped) WHAT IT DOES Interrupts ignition circuit Slows jackshaft Interrupts ignition circuit Floods engine Interrupts ignition circuit Interrupts ignition circuit THROTTLE CONDITION All All All Half throttle or less All All 65
See page 63 for stopping the snowmobile in the event of an emergency. n Emergency Stopping OPERATION The following chart lists methods for more information about the engine stop switch. SYSTEM Ignition Switch Brake Engine Stop Switch Choke (if equipped) Throttle Safety Switch Tether Switch (if equipped) WHAT IT DOES Interrupts ignition circuit Slows jackshaft Interrupts ignition circuit Floods engine Interrupts ignition circuit Interrupts ignition circuit THROTTLE CONDITION All All All Half throttle or less All All 65
Owners Manual
Page 71
... the end of each ride, park the snowmobile on the towed snowmobile to operate the brake and steering when necessary. For your safety, do not attempt to use the front bumper to pull or drag the snowmobile. WARNING Objects towed with the rear of the snowmobile. Only a stiff metal pole connecting the towed object and the tow hitch on a toboggan or sled...
... the end of each ride, park the snowmobile on the towed snowmobile to operate the brake and steering when necessary. For your safety, do not attempt to use the front bumper to pull or drag the snowmobile. WARNING Objects towed with the rear of the snowmobile. Only a stiff metal pole connecting the towed object and the tow hitch on a toboggan or sled...
Owners Manual
Page 85
... fuel filter at the intervals outlined in the Periodic Maintenance Table beginning on page 72. MAINTENANCE Fuel Injectors Fuel Pump All fuel pump service must be performed by an authorized Polaris dealer. All fuel injector service must be performed by an authorized Polaris dealer. Always check fuel line condition after periods of flow through the filter. 82 Do not attempt to clean or service the fuel injectors. Fuel Filter See your dealer change the oil filter...
... fuel filter at the intervals outlined in the Periodic Maintenance Table beginning on page 72. MAINTENANCE Fuel Injectors Fuel Pump All fuel pump service must be performed by an authorized Polaris dealer. All fuel injector service must be performed by an authorized Polaris dealer. Always check fuel line condition after periods of flow through the filter. 82 Do not attempt to clean or service the fuel injectors. Fuel Filter See your dealer change the oil filter...
Owners Manual
Page 90
Perform the bleeding procedure when the engine is bled properly, they 're not, repeat step 5. Remove the bleed screw from the water outlet manifold and/or the thermostat housing. Reinstall the bleed screw into the manifold. 4. Loosen the bleed screw occasionally to the maximum mark. 2. Stop the engine and check the coolant bottle level. Replace the pressure cap and carefully lower the front...
Perform the bleeding procedure when the engine is bled properly, they 're not, repeat step 5. Remove the bleed screw from the water outlet manifold and/or the thermostat housing. Reinstall the bleed screw into the manifold. 4. Loosen the bleed screw occasionally to the maximum mark. 2. Stop the engine and check the coolant bottle level. Replace the pressure cap and carefully lower the front...
Owners Manual
Page 119
...-925-7100 116 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. Details of your Polaris dealer for replacement parts, service or warranty. Serial number 2. Length of time and conditions of purchase 5. Model number 3. Date of operation 7. Contact your snowmobile and its engine. When contacting us about parts, service, or warranty, always provide the...
...-925-7100 116 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. Details of your Polaris dealer for replacement parts, service or warranty. Serial number 2. Length of time and conditions of purchase 5. Model number 3. Date of operation 7. Contact your snowmobile and its engine. When contacting us about parts, service, or warranty, always provide the...
Owners Manual
Page 122
... rights which vary from the use of transportation to perform warranty service. Engine Oil 1. Your dealer will remain in effect. How to repair Polaris snowmobiles. This warranty gives you specific legal rights, and you may use your snowmobile requires warranty service, you may also have other warranty terms will contact the appropriate personnel at Polaris if additional assistance is YOUR responsibility). however, you...
... rights which vary from the use of transportation to perform warranty service. Engine Oil 1. Your dealer will remain in effect. How to repair Polaris snowmobiles. This warranty gives you specific legal rights, and you may use your snowmobile requires warranty service, you may also have other warranty terms will contact the appropriate personnel at Polaris if additional assistance is YOUR responsibility). however, you...
Owners Manual
Page 123
... by the Owner's manual is highly recommended. Warranty will not apply to snow, water, dirt or other casualty not determined a defect of a defect: Skis Tracks Suspension components Brake components Seat components Clutches and components Steering components Batteries Light bulbs/Sealed beam lamps Idler wheels Ski wear rods Slide rails Finished and unfinished surfaces Carburetor/Throttle body components Engine components Drive belts Hydraulic components Circuit breakers/Fuses Electronic components Warranty applies...
... by the Owner's manual is highly recommended. Warranty will not apply to snow, water, dirt or other casualty not determined a defect of a defect: Skis Tracks Suspension components Brake components Seat components Clutches and components Steering components Batteries Light bulbs/Sealed beam lamps Idler wheels Ski wear rods Slide rails Finished and unfinished surfaces Carburetor/Throttle body components Engine components Drive belts Hydraulic components Circuit breakers/Fuses Electronic components Warranty applies...
Owners Manual
Page 124
... the water pump assembly and components, fan, fan bearings, temperature sensor, gasket and seals. • Non wear related throttle body parts are excluded from coverage. This includes off-season storage as are intake and exhaust manifolds excluding paint coverage. • Electrical coverage is limited to spark plugs, hoses, batteries, controls, and recoil ropes are covered, as listed in the owner's manual or Polaris updates. Gaskets are excluded from coverage. 121 The fuel pump is covered. • Clutches and related clutch...
... the water pump assembly and components, fan, fan bearings, temperature sensor, gasket and seals. • Non wear related throttle body parts are excluded from coverage. This includes off-season storage as are intake and exhaust manifolds excluding paint coverage. • Electrical coverage is limited to spark plugs, hoses, batteries, controls, and recoil ropes are covered, as listed in the owner's manual or Polaris updates. Gaskets are excluded from coverage. 121 The fuel pump is covered. • Clutches and related clutch...
Owners Manual
Page 125
... be required to perform the warranty repair. This policy does not apply to vehicles that have not followed the procedure set out above, your warranty coverage. Notice If your vehicle is registered outside the country of the country where it was purchased, Warranty or Service Bulletin repairs may be done by the basic warranty.) For questions call Polaris Customer Assistance (see...
... be required to perform the warranty repair. This policy does not apply to vehicles that have not followed the procedure set out above, your warranty coverage. Notice If your vehicle is registered outside the country of the country where it was purchased, Warranty or Service Bulletin repairs may be done by the basic warranty.) For questions call Polaris Customer Assistance (see...
Owners Manual
Page 131
... Brake System, Bleeding...92 Brakes ...51, 89-92 Break-In, Engine ...57-58 Bulbs, Replacing ...93 E Electrical Connections...109 Emission Control Information ...69-70 Emission Control Label ...69 Emission Control Maintenance ...69 Engine Break-In...57-58 Engine Protection ...108 Engine Stop Switch ...63 Engine, Starting ...56 Environment Preservation ...6 Exhaust System ...83 Eye Protection ...12 C Cargo System...28 Chaincase Oil...77-78 Clutch Alignment Offset ...94 Clutch Center Distance ...94 Clutch Cover Warning...22 Clutch...
... Brake System, Bleeding...92 Brakes ...51, 89-92 Break-In, Engine ...57-58 Bulbs, Replacing ...93 E Electrical Connections...109 Emission Control Information ...69-70 Emission Control Label ...69 Emission Control Maintenance ...69 Engine Break-In...57-58 Engine Protection ...108 Engine Stop Switch ...63 Engine, Starting ...56 Environment Preservation ...6 Exhaust System ...83 Eye Protection ...12 C Cargo System...28 Chaincase Oil...77-78 Clutch Alignment Offset ...94 Clutch Center Distance ...94 Clutch Cover Warning...22 Clutch...
Owners Manual
Page 132
INDEX I Ice and Snow Build-up ...16 IFS...39 Instrumentation ...30-38 Intake Filters ...81 Intake Silencer ...18 P Parking Brake Lever Lock ...52 Passenger Warning ...23 Polaris Products ...110 Pre-Ride Checklist ...49-55 Pressure Cap Warning ...22 L Lights ...93 Limiter Strap Position ...44 Low Oil Indicator Light ...62 Lubrication ...75-78 Chaincase ...77-78 Driveshaft Bearing ...76 Front Suspension...75 Rear Suspension ...75 Throttle Cable ...76 R Rail Slide Wear...106 Recoil...
INDEX I Ice and Snow Build-up ...16 IFS...39 Instrumentation ...30-38 Intake Filters ...81 Intake Silencer ...18 P Parking Brake Lever Lock ...52 Passenger Warning ...23 Polaris Products ...110 Pre-Ride Checklist ...49-55 Pressure Cap Warning ...22 L Lights ...93 Limiter Strap Position ...44 Low Oil Indicator Light ...62 Lubrication ...75-78 Chaincase ...77-78 Driveshaft Bearing ...76 Front Suspension...75 Rear Suspension ...75 Throttle Cable ...76 R Rail Slide Wear...106 Recoil...
Owners Manual
Page 133
... Switch...48 Throttle Lever ...50, 64 Throttle Safety Switch ...50, 63 Torque Stop ...97 Torsion Spring Preload ...44 Towing...68 Track Alignment ...102 Track Care for Storage...109 Track Inspection ...53, 98 Track Lubrication ...99 Track Replacement ...98 Track Tension ...100-101 Track Warm-Up...59 Track Warning ...23 Track, Deep Lug ...53 Transporting the Snowmobile ...109 Troubleshooting, Drive Belt ...115 Troubleshooting, Engine ...111-113 Troubleshooting, Rear Suspension...
... Switch...48 Throttle Lever ...50, 64 Throttle Safety Switch ...50, 63 Torque Stop ...97 Torsion Spring Preload ...44 Towing...68 Track Alignment ...102 Track Care for Storage...109 Track Inspection ...53, 98 Track Lubrication ...99 Track Replacement ...98 Track Tension ...100-101 Track Warm-Up...59 Track Warning ...23 Track, Deep Lug ...53 Transporting the Snowmobile ...109 Troubleshooting, Drive Belt ...115 Troubleshooting, Engine ...111-113 Troubleshooting, Rear Suspension...