2005 Polaris Deep Snow Factory Service Manual
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- 2005 Polaris Deep Snow Service Manual
Original 2005 Polaris Deep Snow Snowmobiles Factory Service Manual.
This manual includes diagnostics/troubleshooting/repair procedures, hi-resolution images and detailed diagrams.
All information contained in this manual is based on the latest product information available and it is the most complete manual used by authorized Polaris service shops.
Polaris manual part number: 9919302
Models covered:
- TRAIL RMK
- 600 RMK
- 700 RMK
- 800 RMK
- 900 RMK
- 600 SWITCHBACK
- 800 SWITCHBACK
Manual Chapters
1 - SPECIFICATIONS
2 - GENERAL
3 - MAINTENANCE
4 - FUEL/DELIVERY
5 - ENGINE
6 - CLUTCHING
7 - FINAL DRIVE
8 - BRAKE SYSTEM
9 - STEERING
10 - FRONT SUSPENSION
11 - REAR SUSPENSION
12 - CHASSIS
13 - ELECTRICAL
14 - WIRING DIAGRAMS
INDEX
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Full list of manual chapters:
UNDERSTANDING SAFETY LABELS AND INSTRUCTIONS
TABLE OF CONTENTS
CHAPTER 1 - SPECIFICATIONS
TRAIL RMK
600 RMK
700 RMK
800 RMK
900 RMK
600 SWITCHBACK
800 SWITCHBACK
CHAPTER 2-GENERAL
2005 Model Number Designation
Tunnel Decal
Vehicle Identification Number
2005 Publication Part Numbers
General Service Precautions
Standard Torque Specifications
Decimal Equivalents
Tap Drill Sizes
Conversion Chart
Piston Wash and Spark Plug Color
Cylinder Inspections
Piston Measurements
Cylinder Honing
Port Chamfering
Connecting Rod Bearing Inspection
Crankshaft Indexing
Oil Pump Operation and Troubleshooting
Oil Pump Bleeding
Oil Pump Adjustment
Cooling System Overview
900 Fusion Cooling System
CHAPTER 3-MAINTENANCE
Maintenance Program Chart
Air Filter
Water Sediment Trap
Oil Filter
Fuel Filter
Lubrication Points
Suspension Lubrication
Chaincase
Track
Track Tension
Spark Plug Reading
Drive Clutch Removal
Headlight
Bulb Replacement
Handlebar Adjustment
Brake System
Throttle Lever Free Play
General Care
Exhaust System
IQ Air Intake System
Edge Exhaust Valve Maintenance
IQ Exhaust Valve Maintenance
Thermostat / Temperature Sensor
900 Liberty Coolant
900 Liberty Oil Pump/Line Bleeding
Typical Recoil Service
700/800 Liberty Water Pump Service
CHAPTER 4-FUEL/DELIVERY
Fuel Warnings
Mikuni Component Part Numbers
Mikuni TM Jet Needle Overview
Mikuni TM 38/40 Component Explanation
Mikuni TM 38/40 Exploded View
Gasoline Volatility
Two Stroke Pre-Mix Ratio Chart
Fuel Delivery System
Carburetor Component Functions
Float System
Fuel Metering
Carburetor Components
Fuel Delivery
Pilot Jet
Pilot Air Screw
Main Jet
Jetting Guidelines
Throttle Valve
Jet Needle/Needle Jet
Throttle Opening vs Fuel Flow
Mikuni TM Carburetor Service
Disassembly/Assembly
Throttle Synchronization
Choke Adjustments
ACCS
Fuel Pump Maintenance
Carburetor Troubleshooting
900 Liberty
Fuel Rail Bleeding Removal/Installation
Fuel Pump
TPS Setting
Throttle Body
TPS Setting
Injectors
CHAPTER 5-ENGINE
Engine Torque Specifications
550 Torque Patterns
500/600 Torque Patterns
700/800 Torque Patterns
900 Liberty Torque Patterns
Typical Engine Removal
550 Engine Disassembly/Assembly
500/600 Recoil/Stator Removal / Installation
500/600 Engine Disassembly / Assembly
500/600 Oil Pump / Water Pump Disassembly / Assembly
700/800 Recoil/Stator Removal / Installation
700/800 Engine Disassembly / Assembly
900 Engine Removal
900 Recoil/Stator Removal / Installation
900 Engine Disassembly / Assembly
900 Oil Pump / Water Pump Disassembly / Assembly
Reed Valves
CHAPTER 6-CLUTCHING
Clutch Tools
Clutch Operation Explanation
Drive Clutch Springs
Drive Clutch Weights
Drive Clutch Identification
Polaris P--85 Clutch Exploded View
Drive Clutch Removal
Drive Clutch Installation
Drive Clutch
Disassembly/Inspection
Spider Removal / Installation
Assembly
Driven Clutch Types
TEAM Driven Clutch
Removal / Installation
Disassembly
Assembly
Helix Angles and Effects
Spring Data
Drive Belt Data
Belt Inspection
Belt Diagnosis
Belt Deflection / Adjustment
Clutch Offset / Alignment
Torque Stop
CHAPTER 7-FINAL DRIVE
Gearing Charts
Sprockets and Chains
Chaincase
Exploded View
Removal
Bearing Removal/Assembly
Jackshaft Removal/Installation
Drive Shaft Removal/Installation
CHAPTER 8-BRAKE SYSTEM
Hydraulic Brake System Overview
Brake Bleeding / Fluid Change
Hayes Master Cylinder
Master Cylinder
Removal
Inspection
Replacing Cartridge Subassembly
Assembly
Brake Pad Replacement
CHAPTER 9-STEERING
Trail/600/700/800 RMK Front Suspension
600/800 Switchback Front Suspension
900 RMK Front Suspension
Steering Inspection
Camber Definition
Radius Rod and Tie Rod End Procedure
Rod End Engagement Guidelines
IFS Steering Alignment Specifications
Spindle Centering / Set Up Width / Camber Adjustment
Camber Adjustment
Handlebar Centering
Toe Adjustment
Ski Spindle Bushing Removal/Installation
Steering Arm Orientation
Ski Installation
Torsion Bar Removal/Installation
IQ Sway Bar Replacement
Handlebar Torque and Sequence
Carbide to Ski Placement
IQ Spindle Assembly
CHAPTER 10-FRONT SUSPENSION
Front Suspension Set up and Adjustments
IFS Shock Springs
IFS Spring Explanation
Compression Damping Adjustable Shocks
IFS Shock Information
IFS Shock Valving Specifications
IQ Spindle/ Control Arm Replacement
CHAPTER 11-REAR SUSPENSION
Rear Suspension Removal/Installation
Rear Suspension Operation
Rear Suspension Adjustment
Front Torque Arm Limiter Strap Adjustment
Suspension Adjustment Procedures
Rear Torsion Spring Tension
Torsion Spring Types
Optional Torsion Springs
Hi-fax Replacement
Track Clip Removal
Suspension Points / Torque Specifications
Suspension Components
Switchback/RMK 136' Suspension Set Up
RMK 144"/151"/159"/166" Suspension Set Up
Front Torque Arm Limiter Strap Adjustment
Rear Shock Information
Rear Shock Valving
Valving Part Numbers
Shock Rebuilding Tools
Shock Valving Arrangement
Gas Shock Maintenance
Ryde FX Shock Rebuilding
Troubleshooting
CHAPTER 12 CHASSIS
Edge Hood Removal/Installation
Edge Headlight Removal/Installation
Edge Instrument Removal/Installation
900 RMK Hood ExplodedView
900 RMK Hood Removal/Installation
900 RMK Front Bumper Removal/Installation
900 RMK Headlight Removal/Installation
900 RMK MFD Removal/Installation
900 RMK Seat / Fuel Tank Exploded Veiw
900 RMK Fuel Tank Removal
900 RMK Console
Seat Cover Removal/Installation
Hood Repair
Tool Flap Repair
Tail Light Assembly Replacement
Nosepan Replacement
Decal Removal/Installation
CHAPTER 13-ELECTRICAL
Typical Multimeter Usage
Ignition Timing Explanation
Ignition Timing Specification Chart
Timing Procedure
Preparing a New Battery
Load Test
Charging Procedure
Testing Electric Start
Starter Motor Testing
Starter Housing and Coil Inspection
Starter Assembly
Starter Solenoid Test
Starter Installation
Unregulated Voltage
Short Circuit Current
Regulated Voltage
Headlight Bulb Test
HI/LO Beam Switch Testing
Seat Harness Troubleshooting
Switch Testing
Troubleshooting
500/600/700/800 Liberty TPS setting
900 Liberty TPS setting
900 Liberty Temperature Light
900 Liberty DET
IQ Coolant Temperature
IQ Exhaust Temperature Sensor
IQ Crank Position Sensor
IQ Speed Sensor
Oil Level Sender
IQ Engine Chassis Connection Location
ECU Plug #1
ECU Plug #2
IQ Stator
IQ Coil / EV Solenoid
IQ Regulator Rectifier
IQ Capacitor
IQ Chassis Relay
Chassis Hood Connections
Diagnostic Ports
CHAPTER 14-WIRING DIAGRAMS
INDEX
Numbers
A-C
D-H
H-O
O-T
T-W
