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2014 Polaris 800 Pro RMK Owners Manual

2014 Polaris 800 Pro RMK Manual

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2014 Polaris 800 Pro RMK | Owners Manual - Page 1
419 Modifications to this snowmobile are not recommended and may result in voided warranty coverage. Please read the warranty section of this manual carefully. IMPORTANT NOTICE TO OWNER 600 RMK 600 PRO RMK 800 RMK 800 PRO RMK 800 RMK ASSAULT Snowmobile Owner's Manual for Maintenance and Safety
2014 Polaris 800 Pro RMK | Owners Manual - Page 2
WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. WARNING The engine exhaust from this product
2014 Polaris 800 Pro RMK | Owners Manual - Page 3
operation of your vehicle, be sure to follow the instructions and recommendations in this owner's manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory certified Master
2014 Polaris 800 Pro RMK | Owners Manual - Page 4
and/or procedures contained within, whether whole or in part, is expressly prohibited. The original instructions for this vehicle are in English. Other languages are provided as translations of the original instructions. Printed in U.S.A. 600 RMK / 600 PRO RMK / 800 RMK / 800 PRO RMK / 800 RMK
2014 Polaris 800 Pro RMK | Owners Manual - Page 5
identification numbers that should be recorded in the owner's manual. Safety ...8 This section describes safe vehicle operation and identifies in your snowmobile's regular maintenance. Specifications ...POLARIS Products...Troubleshooting ...Warranty ...Maintenance Log ...Index ... 118 122 123 127
2014 Polaris 800 Pro RMK | Owners Manual - Page 6
4
2014 Polaris 800 Pro RMK | Owners Manual - Page 7
when the snowmobile is sold. Some of the illustrations and photos used in this manual are general representations. Your model may differ. Follow the maintenance program outlined in this manual. Preventive maintenance ensures that critical components of the snowmobile are inspected by your dealer
2014 Polaris 800 Pro RMK | Owners Manual - Page 8
of our environment, including wildlife and vegetation. Snowmobile clubs and other organizations are working together to protect our environment. Please support their efforts and operate your snowmobile with consideration for the protection and preservation of our environment. Noise Level One of the
2014 Polaris 800 Pro RMK | Owners Manual - Page 9
INTRODUCTION Vehicle Identification Numbers Record your snowmobile's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a POLARIS key blank with one of your existing keys, so if both keys are lost
2014 Polaris 800 Pro RMK | Owners Manual - Page 10
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 indicates a potential personal injury hazard. DANGER A DANGER indicates a hazardous situation that, if not avoided, will result in
2014 Polaris 800 Pro RMK | Owners Manual - Page 11
SAFETY Operator Safety Follow the recommended maintenance program beginning on page 79 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals. WARNING Driving a snowmobile requires your full
2014 Polaris 800 Pro RMK | Owners Manual - Page 12
warming up the track. A loose track or flying debris could cause serious injury or death. We recommend having your dealer perform all track service and alignment procedures. NO STEP Stay Clear of Engine Never attempt adjustments with the engine running. Turn off the ignition, open the side panels
2014 Polaris 800 Pro RMK | Owners Manual - Page 13
SAFETY Operator Safety Riding Apparel Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.
2014 Polaris 800 Pro RMK | Owners Manual - Page 14
bag, a flashlight, food and water, a signaling mirror, a means of building a fire, and a two-way radio or cellular telephone. Always carry the owner's manual on your snowmobile. For added protection, purchase and carry the following items on your snowmobile as well Spare Drive Belt Extra Set of
2014 Polaris 800 Pro RMK | Owners Manual - Page 15
SAFETY Operator Safety Rider Capacity This snowmobile is designed for a single rider only. Never carry a passenger on this snowmobile. Excessive Speed WARNING! High speed driving, especially at night, could result in serious injury or death. Always reduce speed when driving at night or in inclement
2014 Polaris 800 Pro RMK | Owners Manual - Page 16
if you break through the ice. Never travel on frozen bodies of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the snowmobile, you and your cargo, together with any other vehicles in your party. Always check with local authorities
2014 Polaris 800 Pro RMK | Owners Manual - Page 17
SAFETY Operator Safety Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain Take an avalanche class Travel with experienced people Travel on designated trails Make sure each person is equipped with a shovel, probe and avalanche beacon. You
2014 Polaris 800 Pro RMK | Owners Manual - Page 18
may interfere with the steering of your snowmobile, 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 not interfering with full left and right steering. If difficulty
2014 Polaris 800 Pro RMK | Owners Manual - Page 19
SAFETY Operator Safety Driving Downhill When riding downhill, shift your weight to the rear of the snowmobile 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 snowmobile and keep it from rolling freely
2014 Polaris 800 Pro RMK | Owners Manual - Page 20
removed. NOTICE: 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 clutch is a complex mechanism that rotates at high speeds. Each clutch is dynamically balanced
2014 Polaris 800 Pro RMK | Owners Manual - Page 21
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 snowmobile and with what it will and won't do under various conditions.
2014 Polaris 800 Pro RMK | Owners Manual - Page 22
SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding. WINDCHILL CHART (°F) Wind Speed 40 in MPH Calm 5 10 15 20 25 30 35 40 45 50 55 60 40 36 34 32 30 29 28 28 27 26 26 25 25 Actual Thermometer
2014 Polaris 800 Pro RMK | Owners Manual - Page 23
of the labels depicted in this manual differ from the labels on your snowmobile, always read and follow the instructions of the labels on the snowmobile. guard removed. Never run engine with drive belt removed. Never service clutches yourself. See your dealer. Pressure Cap Warning This warning
2014 Polaris 800 Pro RMK | Owners Manual - Page 24
backing up. • Avoid sharp turns. • Shift to or from reverse only when stopped. • Apply throttle slowly. NOTE: For more information, see Owner's Manual. If electric reverse: • Machine stopped and engine at idle, push yellow button on LH control to reverse. Flashing light on dash indicates reverse
2014 Polaris 800 Pro RMK | Owners Manual - Page 25
SAFETY Safety Labels and Locations Track Warning The track warning label is on the rear tunnel: WARNING 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. Hot Surface Warning Track Warning Hot Surface Warning
2014 Polaris 800 Pro RMK | Owners Manual - Page 26
on the console. Operation Warning WARNING • 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 replacement. • This vehicle is capable of high speeds. Buried objects or uneven terrain can
2014 Polaris 800 Pro RMK | Owners Manual - Page 27
stop. • To maintain vehicle control on ice or hard-packed surfaces, you should have a proper balance of ski carbides to track studs. See Owner's Manual for proper use of traction products. • Repeated stops from high speed may cause fading or sudden loss of braking ability. • Parking brake may relax
2014 Polaris 800 Pro RMK | Owners Manual - Page 28
FEATURES 7 8 9 10 11 6 5 4 3 2 12 13 14 15 1 1. 2. 3. 4. 5. 6. 7. Nosepan Skis Front Bumper Hood Headlight Windshield (accessory) Handlebar 8. 9. 10. 11. 12. 13. 14. 15. Operator Seat Taillight Rear Bumper Snow Flap Suspension Track Side Panel Side Panel Fasteners 26
2014 Polaris 800 Pro RMK | Owners Manual - Page 29
FEATURES 2 3 4 5 6 1 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. Fuel Filler Cap Instrument Cluster Ignition Switch Engine Stop Switch Throttle Control Recoil Starter Handle Brake Lever Parking Brake Lock Handlebar Grip Warmer Switch Thumbwarmer Switch Electronic Reverse Button Mode Switch
2014 Polaris 800 Pro RMK | Owners Manual - Page 30
FEATURES Storage Bag/Tool Kit A storage bag and tool kit is located under the left side panel between the oil bottle and console. Storage Bag Cargo Storage Never hang heavy items or fuel containers from the rear of the tunnel. Cargo may be stowed only under the seat and as far forward as possible
2014 Polaris 800 Pro RMK | Owners Manual - Page 31
for inspection procedures. Special tools are required to remove and install the QUICKDRIVE belt. Please see your POLARIS dealer for this service, or refer to the instructions provided with the purchase of a new belt. Belt Handling • Store a new belt in original packaging. Remove only when ready for
2014 Polaris 800 Pro RMK | Owners Manual - Page 32
: brakes, clutches, fuel systems, and exhaust systems. Exhaust systems are critical safety areas that must use approved POLARIS parts. Please see your POLARIS dealer for service. 30
2014 Polaris 800 Pro RMK | Owners Manual - Page 33
FEATURES Fuel Type Selection Whenever using ethanol, MTBE or other forms of oxygenated gasolines, the fuel type designation setting must be changed to "Eth" in the gauge. When using the recommended 91 non-ethanol gasoline, always select the "91-non" setting. Whenever in doubt of your fuel purchase,
2014 Polaris 800 Pro RMK | Owners Manual - Page 34
FEATURES Detonation Elimination Technology (DET) The DET system prevents damage to the engine from detonation by going into an engine protection mode whenever the DET system is active. When excessive detonation is detected, the check engine light will illuminate and you may notice decreased engine
2014 Polaris 800 Pro RMK | Owners Manual - Page 35
of severe detonation are outlined in the troubleshooting table below. DET Troubleshooting Cause of DET Activation Poor quality fuel with recommended fuel Replace with recommended fuel See your POLARIS dealer for service Do not add deicers or additives that contain any form of alcohol instructions. 33
2014 Polaris 800 Pro RMK | Owners Manual - Page 36
FEATURES Instrument Cluster Rider Information Center Check Engine Indicator Over-Temperature Indicator High Beam Indicator Park Brake Indicator Low Oil Indicator MODE Button SELECT Button Reverse Indicator The instrument cluster contains indicator lights and the rider information center. The
2014 Polaris 800 Pro RMK | Owners Manual - Page 37
the lights are set to high beam. Parking Brake Indicator This indicator illuminates when the parking brake is engaged. It will also illuminate when the service brake is in use. See page 60. Reverse Indicator This indicator flashes when the transmission is in reverse. See page 75. 35
2014 Polaris 800 Pro RMK | Owners Manual - Page 38
FEATURES Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. The center displays vehicle speed, engine speed, odometer, resettable trip meters (2), total engine hours of operation, fuel level, engine temperature and diagnostic display mode.
2014 Polaris 800 Pro RMK | Owners Manual - Page 39
FEATURES Instrument Cluster Rider Information Center 1. Information Display Area - This area displays either engine speed or vehicle speed (whichever is not displayed in the speed display), engine temperature and maximum vehicle speed. To change the display, see page 38. 2. Speed Display - The speed
2014 Polaris 800 Pro RMK | Owners Manual - Page 40
FEATURES Instrument Cluster Rider Information Center Speed Display Area The speed display area displays either vehicle speed or engine speed. Vehicle speed is displayed in either miles per hour (MPH) or kilometers per hour (km/h). Engine speed is displayed in revolutions per minute (RPM). 1. To
2014 Polaris 800 Pro RMK | Owners Manual - Page 41
FEATURES Instrument Cluster Rider Information Center Odometer/Engine Hour Display Area This area displays the odometer, Trip A meter, Trip B meter and engine hours meter. The odometer displays the total distance traveled by the vehicle since manufacture. Each trip meter records the distance traveled
2014 Polaris 800 Pro RMK | Owners Manual - Page 42
FEATURES Instrument Cluster Rider Information Center Standard/Metric Display The odometer and temperature displays can be viewed in either standard or metric units of measurement. Both displays change if units are changed. The new settings will remain until changed by the operator. Change Method 1
2014 Polaris 800 Pro RMK | Owners Manual - Page 43
FEATURES Instrument Cluster Rider Information Center Security System (Ignition Lock System) This system is an optional feature and will not function until it has been activated by your authorized POLARIS dealer. If you have this feature activated, you can lock the ignition to prevent unauthorized
2014 Polaris 800 Pro RMK | Owners Manual - Page 44
FEATURES Instrument Cluster Rider Information Center Security System (Ignition Lock System) First Time Use of Your Security System Perform all tasks in the order shown if you wish to activate and use the optional security system. TASK 1: Activate the security system See your authorized POLARIS
2014 Polaris 800 Pro RMK | Owners Manual - Page 45
FEATURES Instrument Cluster Rider Information Center Security System (Ignition Lock System) First Time Use of Your Security System TASK 3: Unlock the System 1. When the engine is running, the display will alternate between SECURE ON and ENTER CODE. Wait until ENTER CODE displays, then press and
2014 Polaris 800 Pro RMK | Owners Manual - Page 46
FEATURES Instrument Cluster Rider Information Center Security System (Ignition Lock System) Locking the System With Your Personal Security Code 1. Start the engine and lock the parking brake. 2. Press and hold the MODE and SEL buttons for 3 seconds, then release. SECURE OFF should be displayed. If
2014 Polaris 800 Pro RMK | Owners Manual - Page 47
FEATURES Instrument Cluster Rider Information Center Security System (Ignition Lock System) Unlocking the System With Your Personal Security Code 1. When the engine is running, the display will alternate between SECURE ON and ENTER CODE. Wait until ENTER CODE displays, then press and release SEL to
2014 Polaris 800 Pro RMK | Owners Manual - Page 48
FEATURES Instrument Cluster Rider Information Center Security System (Ignition Lock System) Changing to a New Security Code Any time you wish to change your current security code to a new code, perform TASK 2 through TASK 4 of the First Time Use of Your Security System procedure beginning on page
2014 Polaris 800 Pro RMK | Owners Manual - Page 49
FEATURES Instrument Cluster Rider Information Center Diagnostic Display Mode The diagnostic display mode is for informational purposes only. Please see your POLARIS dealer for all major repairs. The diagnostic mode is accessible only when the check engine warning indicator is illuminated and a
2014 Polaris 800 Pro RMK | Owners Manual - Page 50
FEATURES Instrument Cluster Rider Information Center Diagnostic Display Code Definitions Open Load: There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed. Short-to-Ground: The wire is shorted to ground between the electronic
2014 Polaris 800 Pro RMK | Owners Manual - Page 51
FEATURES Instrument Cluster Rider Information Center Diagnostic Display Code Definitions Diagnostic Codes Component ECU Memory Injector 1 (MAG) (Port Injector) Injector 2 (PTO) (Port Injector) Knock Sensor 1 Ignition Coil Primary Driver 1 (MAG) Fuel Pump Driver Circuit Knock Level Cylinder 1 (MAG)
2014 Polaris 800 Pro RMK | Owners Manual - Page 52
THE PERFECT FIT Suspension Adjustments Factory settings, combined with user adjustments to the rear track shock spring (RTSS), should be all that's necessary to provide the best riding experience for most riders. The primary adjustment for overall vehicle balance is RTSS preload. Perform this
2014 Polaris 800 Pro RMK | Owners Manual - Page 53
THE PERFECT FIT Suspension Adjustments For riders who weigh 160-220 lbs. (73-100 kg), test ride at factory settings, then make fine-tuning adjustments. See page 52. For riders outside the 160-220 lbs. (73-100 kg) weight range, adjust the factory-set preload to the following installed lengths as a
2014 Polaris 800 Pro RMK | Owners Manual - Page 54
THE PERFECT FIT Suspension Adjustments Fine-Tuning Your Suspension Set-Up The primary adjustment for overall vehicle balance is RTSS preload. Adjust the factory-set preload to the recommended setting for your weight and then test ride. Additional minor adjustments can then be made to the spring
2014 Polaris 800 Pro RMK | Owners Manual - Page 55
THE PERFECT FIT Suspension Adjustments Shock Compression Damping (RMK/ASSAULT RMK) The primary adjustment for overall vehicle balance is RTSS preload. Perform this adjustment first. See page 50. After adjusting RTSS preload to your satisfaction, compression damping adjustments can be made to control
2014 Polaris 800 Pro RMK | Owners Manual - Page 56
THE PERFECT FIT Suspension Adjustments Independent Front Suspension and Front Track Shock Spring Preload (RMK/PRO-RMK) Factory settings, combined with user adjustments to the rear track shock spring, should be all that's necessary to provide the best riding experience for most riders. The primary
2014 Polaris 800 Pro RMK | Owners Manual - Page 57
THE PERFECT FIT Handlebar Adjustments Loosen top bolts to adjust handlebar angle Loosen bottom bolts to adjust handlebar position (if equipped) Handlebar Position (if equipped) 1. Loosen the four bolts on the bottom of the adjuster block. If necessary, pry the blocks apart with a screwdriver. 2.
2014 Polaris 800 Pro RMK | Owners Manual - Page 58
PRE-RIDE INSPECTIONS Pre-Ride Checklist Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined on the referenced pages. Item Drive Belt or QUICKDRIVE Belt Steering System Recoil Rope Coolant Level Chaincase Oil Level Injection
2014 Polaris 800 Pro RMK | Owners Manual - Page 59
your snowmobile's reliability and cause needless repairs and down time. Before beginning any snowmobile trip, a visual inspection will uncover potential problems. Check the following items on a weekly basis or before any long trip. Item Check suspension mounting bolts for tightness. Check rear
2014 Polaris 800 Pro RMK | Owners Manual - Page 60
and Understand Your Owner's Manual Read the Owner's Manual completely and refer to it often. The manual is your guide to safe and enjoyable lever freeplay, DO NOT start the engine. Have the throttle serviced immediately. Throttle Safety Switch Test the throttle safety switch system before the
2014 Polaris 800 Pro RMK | Owners Manual - Page 61
indicates low brake fluid level or air in the hydraulic system. Refer to the brake bleeding information on page 98 or see your dealer for service. 1/2 in. (1.3 cm) Lever Feel If the brake lever feels "spongy" when squeezed, check the brake fluid level and condition. Add fluid as needed. See page
2014 Polaris 800 Pro RMK | Owners Manual - Page 62
is in use. If the parking brake light does not come on when the parking brake or service brake is in use, have it serviced by your dealer. Lock Release To release the lock, squeeze the brake lever tightly. The lock will return to the unlocked position. WARNING! If the
2014 Polaris 800 Pro RMK | Owners Manual - Page 63
may interfere with the steering of your snowmobile, 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 not interfering with full left and right steering. If difficulty
2014 Polaris 800 Pro RMK | Owners Manual - Page 64
PRE-RIDE INSPECTIONS Start the Engine and Check Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never engage the starter when the engine is running. Never start the engine without checking all vehicle components to be sure of proper operation. See
2014 Polaris 800 Pro RMK | Owners Manual - Page 65
OPERATION Starting the Engine NOTICE: Engaging the starter when the engine is running WILL result in serious engine damage, especially if the transmission is in reverse. Never engage the starter when the engine is running. 1. Turn the key to the ON position. 2. Pull the engine stop switch up to the
2014 Polaris 800 Pro RMK | Owners Manual - Page 66
OPERATION Starting the Engine Restarting an Engine If the rider stops the engine by pushing the engine stop switch down, restart the engine using the normal starting procedure. If the engine fails to start using the normal procedure: 1. Push the engine stop switch down to the OFF position. 2. Turn
2014 Polaris 800 Pro RMK | Owners Manual - Page 67
OPERATION Break-In Period Engine Break-In Always follow these recommended break-in procedures for new or rebuilt engines. The first tank of fuel is considered the break-in period for the engine. Premix the first tank of fuel and fill the oil reservoir as outlined below. Oil added to the fuel and oil
2014 Polaris 800 Pro RMK | Owners Manual - Page 68
OPERATION Break-In Period Engine Break-In Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts. Do not operate at full throttle or high speeds for extended periods during the first three hours of use. Vary the throttle openings and vehicle speeds to
2014 Polaris 800 Pro RMK | Owners Manual - Page 69
OPERATION Break-In Period Drive Belt/QUICKDRIVE Belt Break-In The length of the break-in period varies depending on the type of drive system. The break-in period for a new drive belt is 30 miles (48 km). The break-in period for a new QUICKDRIVE belt is 100 miles (160 km). • Vary the throttle
2014 Polaris 800 Pro RMK | Owners Manual - Page 70
before operating the snowmobile. Follow these steps to ensure proper warm-up of the engine, drive train and track. 1. Use an appropriate stand to securely support the rear of the snowmobile at the rear bumper. The track should be about 4 inches (10 cm) off the ground. 2. Start the engine and allow
2014 Polaris 800 Pro RMK | Owners Manual - Page 71
OPERATION Fuel WARNING Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline. Always refuel outdoors or in a well-ventilated area. Always turn off the engine before refueling. Do not overfill the tank. Do not fill the tank
2014 Polaris 800 Pro RMK | Owners Manual - Page 72
OPERATION Fuel Recommendation For peak performance, POLARIS recommends the use of 91 octane fuel or higher, with no ethanol. Although 87 octane fuel is usable, some engine performance will be lost and fuel economy will decrease. Do not use lower than 87 octane fuel. Do not use fuel containing more
2014 Polaris 800 Pro RMK | Owners Manual - Page 73
OPERATION Oil Low Oil Level Always maintain the oil level between the "add" mark and the bottle neck. Do not fill the bottle neck. See page 65 for oil recommendations. 1. Immediately stop the engine if the low oil indicator light comes on. 2. Open the left side panel. 3. View the oil level in the
2014 Polaris 800 Pro RMK | Owners Manual - Page 74
OPERATION Engine Stop Switch Push down on the engine stop switch to ground out the ignition and stop the engine quickly. Pull the switch up to the ON position to allow restarting. Stop Switch Throttle Safety Switch The throttle safety switch is designed to stop the engine whenever all pressure is
2014 Polaris 800 Pro RMK | Owners Manual - Page 75
may cause the safety switch to activate, preventing the engine from starting. If this occurs, return the snowmobile to an authorized POLARIS dealer for service. If an emergency exists and it's necessary to start the engine, the throttle safety switch and engine stop switch may be disconnected from
2014 Polaris 800 Pro RMK | Owners Manual - Page 76
OPERATION Electronic Reverse (PERC) WARNING Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Damage will occur to the chaincase or transmission if shifting is attempted when the engine is operating above idle speed. • Shift to or from
2014 Polaris 800 Pro RMK | Owners Manual - Page 77
OPERATION Electronic Reverse (PERC) Engaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Make sure the area behind your vehicle is clear. 3. Push the yellow reverse button on the left-hand control for one second, then release. The engine will automatically reduce RPM and start a
2014 Polaris 800 Pro RMK | Owners Manual - Page 78
OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 72 for more information about the engine stop switch and throttle safety switch. SYSTEM Ignition Switch Brake Engine Stop Switch Throttle Safety Switch Tether Switch (
2014 Polaris 800 Pro RMK | Owners Manual - Page 79
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 inches (10 cm) off the ground. Remove the key and
2014 Polaris 800 Pro RMK | Owners Manual - Page 80
and it comes on, you must take your snowmobile to a qualified dealer for diagnostic service. Specifications and adjustments for engine tune-ups are located in the Service Manual, which is available to your qualified service technician. Reverse (if equipped) must not be engaged during engine tune-ups
2014 Polaris 800 Pro RMK | Owners Manual - Page 81
MAINTENANCE POLARIS Recommended Maintenance Program To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as outlined in this manual. Record maintenance and service in the Maintenance Log beginning on page 135. The recommended
2014 Polaris 800 Pro RMK | Owners Manual - Page 82
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
2014 Polaris 800 Pro RMK | Owners Manual - Page 83
MAINTENANCE Periodic Maintenance Interval Table Item See Page Frequency 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi. (3200 km) PreSeason BRAKES Hose Routing Hose Condition Fluid Leaks Brake Pads Brake Disc Parking Brakes Brake System Brake Fluid Idle RPM Throttle Lever Oil Pump
2014 Polaris 800 Pro RMK | Owners Manual - Page 84
MAINTENANCE Periodic Maintenance Interval Table Item See Page Frequency 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi. (3200 km) PreSeason CHASSIS Ski Toe Alignment Suspension Mounting Bolts Bolt Torques Rear Suspension Fasteners Steering Fasteners Suspension Shock Oil Cooling Fins
2014 Polaris 800 Pro RMK | Owners Manual - Page 85
, pull the panel outward to release the tabs at the lower edge of the panel. 1/4-Turn Fasteners Strap Removing the hood is not recommended. Any service requiring the removal of the hood should be performed by an authorized POLARIS dealer. 83
2014 Polaris 800 Pro RMK | Owners Manual - Page 86
MAINTENANCE Lubrication Rear Suspension Lubricate the suspension pivot shafts with POLARIS All Season Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 80 and before seasonal storage. When operating in heavy, wet snow conditions, lubricate every 500 miles (800 km).
2014 Polaris 800 Pro RMK | Owners Manual - Page 87
MAINTENANCE Lubrication Chaincase Oil Check and change the chaincase oil at the intervals outlined in the maintenance charts beginning on page 79. Maintain the oil level at the top of the fill plug hole. POLARIS recommends the use of POLARIS Synthetic Chaincase Lube. See page 122 for the part
2014 Polaris 800 Pro RMK | Owners Manual - Page 88
MAINTENANCE Lubrication Driveshaft Bearing (RMK/ASSAULT RMK) Inject grease into the fitting on the speedometer sensor housing until grease purges from the seal on the inside of the tunnel. This should take approximately two pumps. Do not use more than four pumps. Fitting 86
2014 Polaris 800 Pro RMK | Owners Manual - Page 89
performance. Always store fuel in clean fuel containers. If low fuel pressure or reduced engine performance occurs between the recommended fuel filter service intervals, the filter may need replacement. See your dealer. Inspect the fuel lines regularly for signs of deterioration or damage. Always
2014 Polaris 800 Pro RMK | Owners Manual - Page 90
MAINTENANCE Spark Plugs Spark Plug Recommendations A new engine can cause temporary spark plug fouling due to the preservative added during the assembly process. Avoid prolonged idle speeds, which cause plug fouling and carbonization. Refer to the specifications section for the specific spark plug
2014 Polaris 800 Pro RMK | Owners Manual - Page 91
be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. TIP: The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetor/throttle
2014 Polaris 800 Pro RMK | Owners Manual - Page 92
MAINTENANCE Oil Lines Inspect oil line condition every 1000 miles (1600 km) as outlined in the maintenance charts beginning on page 79. Oil Filter Please see your dealer for replacement of the in-line oil filter every 2000 miles (3200 km) as outlined in the maintenance charts beginning on page 79.
2014 Polaris 800 Pro RMK | Owners Manual - Page 93
MAINTENANCE Cooling System Coolant The coolant supplied in the system at the factory is a 50/50 mixture of ethylene-glycol and distilled water, which will provide adequate freeze protection under most conditions. If the vehicle will be stored or operated at extremely low temperatures, greater
2014 Polaris 800 Pro RMK | Owners Manual - Page 94
coolant maintains its ability to protect the engine, drain the system completely every two years and add a fresh mixture of antifreeze and distilled water. This service must be performed when the engine is cold. Ask your POLARIS dealer to check the coolant when he performs the fall tune-up on your
2014 Polaris 800 Pro RMK | Owners Manual - Page 95
MAINTENANCE Cooling System Bleeding the Cooling System CAUTION! Steam and hot liquids will cause burns to your skin. Never bleed the cooling system or remove the pressure cap when the engine is warm or hot. Use of a non-standard pressure cap will not allow the recovery system to function properly.
2014 Polaris 800 Pro RMK | Owners Manual - Page 96
and remove the hood. See page 83. 2. Inspect the muffler and pipes for cracks or damage. 3. Check for weak or missing retaining springs or damper/support grommets. 4. Check for loose clamps on the pipe covers. 94
2014 Polaris 800 Pro RMK | Owners Manual - Page 97
MAINTENANCE Drive Chain Tension (RMK/ASSAULT RMK) Check drive chain tension weekly and before each long trip. 1. Remove the side panels. 2. Rotate the driven clutch counter-clockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever
2014 Polaris 800 Pro RMK | Owners Manual - Page 98
MAINTENANCE Brakes Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 59. Brake pads must be replaced when the brake pad material becomes thinner than the backing plate (approximately 1/16 inch or 1.5 mm). A kit is available for replacing brake
2014 Polaris 800 Pro RMK | Owners Manual - Page 99
MAINTENANCE Brakes Brake Fluid The brake fluid level can be seen through a plastic sight glass in the brake reservoir. If the fluid is sufficient, the sight glass will be black. If the sight glass is any color other than black, add brake fluid. Replace brake fluid at least every two years with
2014 Polaris 800 Pro RMK | Owners Manual - Page 100
MAINTENANCE Brakes 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 accident and
2014 Polaris 800 Pro RMK | Owners Manual - Page 101
MAINTENANCE Lights When servicing a halogen lamp, avoid touching the lamp with bare fingers. Oil from your skin 6. Secure the foam shield. Taillight/Brake Light Replacement The taillight assembly is not serviceable. If the light fails to operate properly, replace the entire taillight assembly. 99
2014 Polaris 800 Pro RMK | Owners Manual - Page 102
be damaged if lubricated. Do not lubricate clutch bushings. Clutch Alignment Offset Clutch alignment offset is important for maintaining optimum performance. See your dealer for service and adjustments. A special tool is required to check for proper alignment. 100
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wear or damage. Special tools are required to remove and install the QUICKDRIVE belt. Please see your POLARIS dealer for this service, or refer to the instructions provided with the purchase of a new belt. Improper track tension can result in track ratcheting, which will affect QUICKDRIVE belt
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MAINTENANCE Clutch System Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge (1) on the belt and apply downward pressure while measuring at point 2. This measurement should be 1 1/4 inches (3.2 cm). 2 1 Drive Belt
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MAINTENANCE Clutch System Drive Belt Removal NOTICE: Do not attempt to remove the drive belt after operating in reverse. The snowmobile must be stopped after forward motion to prevent damage to components during belt removal. Rotate the driven clutch counterclockwise 1/4 turn by hand to ensure
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MAINTENANCE Clutch System Drive Belt Installation 1. With the L-wrench inserted into the threaded hole and the sheaves in the open position, install the drive belt. TIP: Install the belt so that the numbers can be read correctly on the left side of the vehicle, or in the direction in which the belt
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Never rotate a damaged track under power. 1. Using a hoist, safely lift and support the rear of the snowmobile off the ground. 2. Rotate the track by hand ! Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure, loss of vehicle control and
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adjustments should be made only after the track is warmed up and limber. 1. Turn the engine off. 2. Lift the rear of the snowmobile and safely support it off the ground. 3. Place the recommended weight or downward pressure on the track at the specified distance (see chart) ahead of the center of
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MAINTENANCE Track Maintenance Track Tension 5. Check for specified slack between the wear surface of the track clip and the plastic slider. Refer to the Track Tension Data Chart on page 106. If the track needs adjustment: 6. Loosen the rear idler shaft bolt. 7. Loosen the locknuts. Adjusting Screw
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check that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. 1. Safely support the rear of the snowmobile with the track off the ground. 2. Start the engine and apply a small amount of throttle until the track turns
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MAINTENANCE Steering System Steering Inspection Each week, or before a long ride, check all steering system fasteners and tighten if necessary. 109
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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. 1. Place the handlebars in a straight-ahead
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when worn to half their original diameter. TIP: Carbide skags must be replaced if any abnormal wear or chipping is found. Skag Replacement 1. Raise and support the front of the snowmobile so the skis are approximately 6 inches (15.2 cm) from the ground. 2. Remove the attaching nuts and pry the skag
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MAINTENANCE Steering System Rail Slide Wear For ease of inspection, all POLARIS rail slides have a wear limit indicator groove to indicate the minimum permissible slide thickness. Replace the rail slides if they are worn to the top of the groove at any point along their length. Failure to do so may
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not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 115 before installing the battery. 1. 2. 3. 4. 5. 6. Ensure that the battery is fully charged. Set the battery in the battery holder
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the battery if the voltage drops below a pre-determined point. Battery Charging The following battery charging instructions apply only to the installation of a sealed battery. Read all instructions before proceeding with the installation of this battery. The sealed battery is already filled with
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or less until the battery voltage is 12.8 or greater. Tip: When using an automatic charger, refer to the charger manufacturer's instructions for recharging. When using a constant current charger, use the following guidelines for recharging. WARNING! An overheated battery may explode, causing severe
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MAINTENANCE Fall Tune-Up For maximum performance, arrange for a fall service tune-up with your POLARIS dealer. His experienced and trained service technician will keep your snowmobile in peak operating condition. Transporting the Snowmobile Whenever the snowmobile is transported: 1. Be sure the
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driven clutch shaft bushing as outlined in the Master Repair Manual. See your dealer. Engine Protection Proper preparation of the fogging oil. Follow the engine fogging instructions provided on the container. Always add Carbon Clean or supported off the ground to allow the track to hang freely
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SPECIFICATIONS 600 RMK / 600 PRO RMK Capacities and Dimensions Body Style Rider Capacity Coolant Capacity Chaincase Oil Capacity Fuel Tank Capacity Gearcase Oil Capacity (oz./ml) Oil Capacity (qts./l) Height Length Designed Width (in./cm) Brake Type Drive Clutch Center Distance Drive Belt P/N Drive
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SPECIFICATIONS 600 RMK 144 / 600 RMK 155 Clutching Chart ALTITUDE Meters (Feet) Drive Clutch Drive Clutch Driven Clutch Shift Weight Spring Spring Driven Helix Chaincase Gearing/ Pitch *Shaded cells indicate factory settings. 0-450 (0-1500) 450-900 (1500-3000) 900-1500 (3000-5000) 1500-2100 (5000-
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SPECIFICATIONS 800 RMK / 800 PRO RMK / 800 RMK ASSAULT Capacities and Dimensions Body Style Rider Capacity Coolant Capacity PRO-RIDE 1 6.3 qts. (6.0 l) (RMK 155) 5.3 qts. (5.0 l) (PRO RMK 155) 5.3 qts. (5.0 l) (RMK ASSAULT 155) 5.5 qts. (5.2 l) (PRO RMK 163) 9 oz. (266.2 ml) (RMK/RMK ASSAULT) N/A (
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SPECIFICATIONS 800 RMK 155 / 800 RMK ASSAULT 155 Clutching Chart ALTITUDE Meters (Feet) Drive Clutch Drive Clutch Driven Clutch Shift Weight Spring Spring Driven Helix Chaincase Gearing/ Pitch *Shaded cells indicate factory settings. 0-600 (0-2000) 600-1200 (2000-4000) 1200-1800 (4000-6000 1800-
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POLARIS PRODUCTS Part No. 2870791 2875035 2875036 2877882 2877953 2877883 2877884 2873105 2873106 2871312 2871322 2871423 2871329 2871534 2871323 2871326 2870652 2872189 2872893 2870505 2872889 2872890 2878018 Description Engine Lubricants Fogging Oil (12 oz. Aerosol) Premium Blue 2-Cycle Oil (qt
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TROUBLESHOOTING Engine Troubleshooting Problem Erratic engine RPM during acceleration or pump. Add isopropyl alcohol to the fuel system. • SEE YOUR DEALER. • This indicates a major engine problem that must be repaired before operating. SEE YOUR DEALER. • Replace the plug(s). • SEE YOUR DEALER. •
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Drive System Troubleshooting Problem Machine fails to move Probable Cause Solution Clutch jammed Track jammed • Check for twisted belt or broken spring. SEE YOUR DEALER. • Foreign object may be
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Drive Belt Troubleshooting Belt Wear/Burn Diagnosis Causes Driving at low RPM Insufficient warm-up Solutions • Drive at higher RPMs. Gear the machine down. Check belt deflection. • Warm
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TROUBLESHOOTING Suspension Troubleshooting Problem Rear suspension bottoms too easily Rides too stiff in rear Solution • Refer to the suspension adjustment and set-up information beginning on page 50. • Revalve
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of purchase 5. Details of trouble experienced 6. Length of time and conditions of operation 7. Previous correspondence Use the page provided near the front of your Owner's Manual to record the identification numbers of your snowmobile and its engine. POLARIS Customer Service United States: 1-888
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preparation and setup of your snowmobile is very important in ensuring trouble-free operation. Purchasing a snowmobile in the crate or without any damages that occur during trailer transit or as a result of unauthorized service or parts. In addition, this warranty does not cover physical damage to
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offered by POLARIS. These warranties can be, but are not limited to: • Two-year extended engine coverage • Two-year powertrain coverage • Extended service contract If you selected any type of extended warranty coverage as part of a POLARIS retail program, please contact any authorized POLARIS dealer
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to perform the required vehicle Pre-Delivery Inspection, perform all applicable service bulletins and have the consumer sign the PDI form prior to delivery products for lubrication and maintenance as directed by the Owner's manual is highly recommended. Should a failure occur during the warranty
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must be done by an authorized POLARIS dealer. If you move or are traveling within the country where your vehicle was purchased, Warranty or Service Bulletin repairs may be requested from any authorized POLARIS dealer who sells the same line as your vehicle. Outside the Country where your vehicle
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it was purchased, and you have not followed the procedure set out above, your vehicle will no longer be eligible for warranty or service bulletin coverage of any kind, other than safety bulletins. (Vehicles registered to Government officials or military personnel on assignment outside of the country
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WARRANTY U.S.A. EPA Emissions Limited Warranty This emissions limited warranty is in addition to the POLARIS standard limited warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it
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responsible for performing the scheduled maintenance identified in the owner's manual. POLARIS may deny warranty claims for failures that have been recommends that you contact an authorized POLARIS dealer to perform any service that may be necessary for your vehicle. POLARIS also recommends that
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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. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 150 mi. (240 km)
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MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 136
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for Storage 117 Coolant ...91 Coolant Level ...91 Cooling System...91-93 Cooling System, Bleeding ...93 Cooling System, Flushing...92 Customer Service ...127 E Electrical Connections Care for Storage 117 Emission Control Information ...78 Emissions Limited Warranty . 133-134 Engine Break-In ...65
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INDEX F Fasteners, Hood and Side Panel...Fluid Change Chaincase ...Coolant ...Fluid Level Brake Fluid ...Chaincase ...Coolant ...Fuel ...Fuel Filter...Fuel Lines ...Fuel Premix (Initial Fill) ...Fuel Pump ...Fuel Recommendation ...Fuel System Deicers ...Fuel Type Selection ...Fuel Warnings ...61 85
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-108 Track Safety ...10 Track Warm-Up ...68 Track Warning ...23 Transporting the Snowmobile...116 Troubleshooting, Drive Belt ...125 Troubleshooting, Drive System ...124 Troubleshooting, Engine...123 Troubleshooting, Suspension ...126 Tune-Up ...116 S Safety Labels...21-24 Safety Symbols ...8 Shock
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PMS 419 For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polaris.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 Phone 1-888-704-5290 Part No. 9924268 Rev 01 Printed in USA *9924268 *