2010 Polaris 800 RMK Assault Owners Manual

2010 Polaris 800 RMK Assault Manual

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  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 1
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 2
    Pantone 425C For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 Phone 1-888-704-5290 Part No. 9922332 Rev 01 Printed in USA
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 3
    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
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 4
    The text is printed on 100% recycled with 40% post-consumer waste (PCW).
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 5
    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
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 6
    inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A. 2010 Owner's Manual P/N 9922332 600/800 RMK 144/155, 700 RMK 155, 800 DRAGON RMK 155/163, 800 ASSAULT RMK 2
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 7
    of important identification numbers that should be recorded in the owner's manual. TABLE OF CONTENTS Safety ...8 This section describes safe vehicle operation your snowmobile's regular maintenance. Polaris Products...110 Troubleshooting ...111 Warranty ...116 Maintenance Log ...125 Index ...128 3
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 8
    4
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    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
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 10
    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
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 11
    Vehicle Identification Numbers INTRODUCTION Record your snowmobile's identification numbers and key number in the spaces provided below. The key number is stamped on the spare key. The number on the rubber-coated key is in the form of raised dots. Remove the spare key and store it in a safe place.
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    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. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 13
    Operator Safety SAFETY Follow the recommended maintenance program outlined beginning on page 71 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
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 14
    while 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. Stay Clear of Engine Never attempt adjustments with the engine running. Turn off the ignition, raise the hood, make the
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 15
    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
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 16
    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.
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    Operator Safety SAFETY Disabled Operators Safe operation of this rider-active vehicle requires good judgement and physical skills. WARNING! Operators with cognitive or physical disabilities have an increased risk of loss of control, which could result in serious injury or death. Do not allow
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 18
    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
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 19
    Operator Safety Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain SAFETY 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.
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    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
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 21
    Operator Safety SAFETY Driving on Slippery Surfaces WARNING! Never attempt an abrupt change of direction when operating on slippery surfaces. Proceed slowly and use extra caution. Driving on ice or hardpacked snow reduces steering and braking control, which may result in loss of control and
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    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 clutch is a complex mechanism that rotates at high speeds. Each clutch is dynamically balanced
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    Operator Safety SAFETY Inadequate Snow Conditions Since snow provides the only lubrication for the power slide suspension and, on liquid cooled models, cooling for the engine, adequate snow cover is a requirement for operation of your snowmobile. NOTICE: Driving in too little snow will result in
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 24
    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.
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    Operator Safety SAFETY Windchill/Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding. WIND CHILL 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
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    of the decals depicted in this manual differ from the decals on your snowmobile, always read and follow the instructions of the decals on the snowmobile. belt guard removed. Never run engine with drive belt removed. Never service clutches yourself. See your dealer. Pressure Cap Warning The pressure
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    Safety Decals and Locations "No Passenger" Warning Snowmobiles designed for only a single rider have a warning decal on the console below the steering post. WARNING This vehicle is designed for operator only. "NO PASSENGER" SAFETY "No Passenger" Warning Track Warning The track warning decal is on
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    console of all Polaris snowmobiles. 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
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 29
    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
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 30
    FEATURES 6 8 7 3 2 1 11 12 13 16 14 15 5 4 9 10 1. Front Bumper (do not use for pulling or dragging the snowmobile) 2. Hood 3. Headlight 4. Windshield 5. Mountain Bar (if equipped) 6. Handlebar 7. Seat 8. Taillights 9. 10. 11. 12. 13. 14. 15. 16. Rear Bumper Snow Flap Track Suspension Tunnel
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    3 4 2 5 6 7 8 FEATURES 1 10 9 11 14 3 4 8 9 13 12 2 5 6 7 13 1. 2. 3. 4. 5. 6. 7. 8. 14 10 12 Fuel Filler Cap Ignition Switch MFD (Multi-Function Display) Engine Stop Switch Throttle Control Recoil Starter Handle Hood Hold-Down Straps Brake Lever 9. Parking Brake 10. Handlebar Grip
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 32
    FEATURES Headlight Dimmer Switch Use the headlight dimmer switch to adjust the headlights between high beam and low beam. Switch headlights to low beam when meeting oncoming traffic. Dimmer Switch Dimmer Switch (Dragon) Adjustable Headlights Move the adjuster to the left to lower the headlight
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 33
    Detonation Elimination Technology (DET) FEATURES A detonation sensor monitors the engine and responds to detonation by automatically reducing the engine timing and adding fuel. This results in decreased engine RPM and performance. Effect of DET The DET system prevents damage to the engine from
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 34
    FEATURES Item Instrumentation MFD Component Identification 1 Analog Gauge (if equipped) 2 Digital Gauge 3 Check Engine Indicator 4 Low Oil Indicator 5 High Temp Indicator 6 Brake Indicator 7 Reverse Indicator 8 High Beam Indicator 1 2 3 4 5 6 7 8 30
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 35
    Instrumentation Item 1 RPM or Speed Altitude (if equipped) Service Interval 2 Electrical System Voltage Level FEATURES Digital Display Identification 1 2 3 MAX - Temp Degrees Celsius Degrees Fahrenheit 5 Miles Kilometers 6 Hours Trip 1/Trip 2/Trip F Service Label Altitude Label 3 4 5 6 31
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 36
    Switch allows you to set the MFD display to your preferences. The rocker switch has a MODE button (top) and a SET button (bottom). Specific instructions are outlined on the following pages. MODE SET MFD Control Switch (Dragon) MFD Control Switch Standard vs. Metric The MFD will display either
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 37
    Instrumentation FEATURES MFD Digital Display Programs Press and release the MODE button to cycle through the three MFD programs: Performance, Engine and History. Each program remains active until you cycle to the next program. While any program is active, press and release the SET button to cycle
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 38
    FEATURES Instrumentation MFD Digital Display Programs Performance Program Trip Settings Trip F automatically displays when the fuel level is low if the snowmobile is equipped with an electronic fuel gauge. The fuel symbol and the last fuel bar on the MFD gauge (if equipped) will blink when the
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 39
    Instrumentation FEATURES MFD Digital Display Programs Engine Program Air Temperature (accessory) The MFD displays actual air temperature. Press and hold the MODE switch for ten seconds to switch between standard and metric units of measurement. Altimeter (accessory) The rider can calibrate the
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 40
    and fuel level (if equipped). Press and release the SET button to cycle through the following screens: maximum vehicle speed, maximum engine RPM and service interval reminder. Maximum Speed/Maximum RPM The gauge automatically logs the maximum speed and engine RPM even if the history program is not
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    will flash in the odometer area and "ENG" will flash in the icon area for five seconds each time the engine is started (until the service reminder is reset.) Use the following procedures to reset the reminder. To reset the reminder at the existing interval: 1. Enter the History Program. 2. Press and
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 42
    FEATURES Instrumentation Gauge Cleaning 1. Wipe the gauge face as needed using a clean cloth and a mild soap and water solution. Wipe dry with clean, soft cloth. 2. Clean the back side of the gauge using a clean cloth and a mild soap and water solution. Do not remove the electrical connectors or
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 43
    IQ Front Suspension Adjustments Independent Front Suspension (IFS) THE PERFECT FIT Break in the suspension for approximately 150 miles (240 km) before making any fine-tuning adjustments. Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 44
    THE PERFECT FIT IQ Front Suspension Adjustments WARNING! Always verify ski alignment before making adjustments to the IFS. See page 104 to check alignment. If the skis are misaligned, see your dealer, as the camber adjustment may also be affected. Air Shocks Walker Evans air shocks can be adjusted
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 45
    IQ Front Suspension Adjustments Assault Shocks The tension at which the shock coil spring is set is called spring preload. For the best ride, the suspension should be adjusted to use the full travel of the shocks with occasional light bottoming. After making spring adjustments, adjust shock clickers
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 46
    THE PERFECT FIT Rear Suspension Adjustments 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 suspension designs
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 47
    Rear Suspension Adjustments To set up the rear suspension torsion spring preload, measure the distance between the ground and rear bumper. This is measurement X. Take this measurement with no rider and with the rear suspension at full extension. TIP: The rear bumper may need to be lifted upward
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 48
    THE PERFECT FIT Rear Suspension Adjustments Torsion Spring Preload To adjust rear torsion spring preload, rotate the three-position cam using the engine spark plug tool. Different rate torsion springs are available if a firmer ride is desired. Contact your dealer for more information. The following
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 49
    Rear Suspension Adjustments Shock Compression Valving Standard Rear Track Shock The standard RMK rear track shock is an Arvin MPV Select shock that allows for adjustments to the compression valving. Adjustments are made by turning the adjustment screw located near the base of the shock. In half-turn
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 50
    THE PERFECT FIT Handlebar Adjustments WARNING! Some aftermarket accessories (including windshields and cargo bags) may interfere with the handlebar. Such accessories could limit your ability to steer the vehicle and/or may contact the brake lever. This could lead to loss of control resulting in
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 51
    Handlebar Adjustments Handlebar Position 1. Loosen the four bolts on the bottom of the adjuster block. If necessary, pry the blocks apart with a screwdriver. 2. Adjust the handlebar forward or rearward to the desired position. 3. Tighten the bolts. THE PERFECT FIT Loosen top bolts to adjust
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 52
    : 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. Tether Switch The accessory tether switch is available for all models. Order part number 2870668. 48
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 53
    Pre-Ride Checklist PRE-RIDE INSPECTIONS Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined on the referenced pages. Look for a checkmark (n) on the referenced pages to locate the pre-ride inspection items. Item Drive Belt
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    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 excessive lever freeplay, DO NOT start the engine. Have the throttle serviced immediately. n Throttle Safety Switch Test the throttle safety switch system
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    needed. See page 91. Check for the presence of air in the fluid system. See page 92 for more information, or see your dealer for service. WARNING! Continued use of "spongy" brakes may cause a complete loss of brakes, which could result in serious injury or death. Always have the brakes
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 56
    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
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 57
    Before Starting the Engine n Steering System PRE-RIDE INSPECTIONS Manually turn the skis completely to the right and to the left. If any difficulty is encountered, remove any ice and snow build-up that may
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 58
    reduce 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 Suspension mounting bolts Rear idler wheel bolts Rear
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 59
    Start the Engine and Check PRE-RIDE INSPECTIONS 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.
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 60
    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. Pull the engine stop switch up to the
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 61
    Engine Break-In OPERATION 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
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 62
    OPERATION Engine Break-In Oil Injection System Always fill the oil reservoir when refueling. NOTICE: Serious engine damage can occur without the proper lubrication. Check the oil tank level often during the first tank of fuel. If the oil level doesn't go down, contact your dealer immediately. Oil
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 63
    warm-up or when the track is free-hanging. Be sure the rear support is stable. WARNING! Use of traction products such as studs, ice growsers, 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
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 64
    OPERATION Fuel Safety 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
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 65
    Fuel OPERATION For peak performance, Polaris recommends the use of 91 octane or higher fuel. 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 than 10% ethanol (including E85
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 66
    OPERATION Oil n Low Oil Indicator Light The low oil indicator light will alert the operator if the oil level is low. Visually check for oil in the bottle. Add oil before further operation of the snowmobile. See page 58 for oil recommendations. NOTICE: Operating the snowmobile without adequate engine
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 67
    n 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 RUN position to allow restarting. OPERATION Stop Switch n Throttle Safety Switch The throttle safety switch is designed to stop the engine whenever all
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 68
    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
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 69
    n Emergency Stopping OPERATION The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 63 for more information about the engine stop switch. SYSTEM Ignition Switch Brake Engine Stop Switch Choke (if equipped) Throttle Safety Switch Tether Switch (if
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 70
    OPERATION WARNING Electronic Reverse (PERC) 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
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 71
    Electronic Reverse (PERC) Engaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Make sure the area behind your snowmobile is clear. 3. Push the reverse button on the lefthand control for one second, then release. The engine will automatically reduce RPM and start a reverse rotation
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 72
    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" (10 cm) off the ground. Remove the key and cover
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 73
    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
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 74
    Information Owner's Responsibilities Please read the Snowmobile Engine Emissions Limited Warranty, and read the maintenance section of your owner's manual. You are responsible for ensuring that the specified maintenance is performed. Polaris recommends that you contact an authorized Polaris dealer
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 75
    Polaris Recommended Maintenance Program MAINTENANCE 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 125. The
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 76
    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
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 77
    Periodic Maintenance Interval Table Item See Page 150 mi. (240 km) 500 mi. (800 km) MAINTENANCE 2000 mi. (3200 km) PreSeason Frequency 1000 mi. (1600 km) BRAKES Hose Routing Hose Condition Fluid Leaks Brake Pads Brake Disc Parking Brake Brake System Brake Fluid Idle RPM Throttle Lever Oil Pump
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    55 102 101 -106 77 I I I R I I I I I I I I I I I I I I I I I I I I I I I I L L I I I I I I L I I I I I I I I I I I I I I I I I C I See your dealer for service at 1500 mi. (2000 km) I I L L I I I I I I L I I I I I I I I I I I L L I I I I I I I I I I I I I I I I L I - Inspect (clean, adjust, tighten
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    Lubrication MAINTENANCE Front Suspension The front suspension does not require lubrication. Rear Suspension Lubricate the suspension pivot shafts with Polaris Premium All Season Grease at the intervals outlined in the Periodic Maintenance Table beginning on page 72 and before seasonal storage.
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    MAINTENANCE Lubrication Driveshaft Bearing 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 Throttle Cable Lubricate the throttle cable
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    Lubrication MAINTENANCE n Chaincase Oil Check the chaincase oil level at the intervals outlined in the maintenance charts beginning on page 71. The sight glass is located on the lower rear of the chaincase. Maintain the oil level at or slightly below the center of the sight glass. Change the
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 82
    MAINTENANCE Lubrication Chaincase Oil Oil Change 1. Position the vehicle on a level surface. 2. Remove the drain plug and drain the oil into a drain pan. Allow the oil to drain completely. 3. Clean off all metal shavings from the plug. 4. Install a new sealing washer on the Drain Plug drain plug.
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 83
    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. The tip should not be white. A white insulator tip indicates overheating, caused by use of an improper spark plug or incorrect carburetor/throttle body
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 84
    engine is operated in conditions more severe than intended for that plug. Always use the spark plugs recommended for your snowmobile. See your Owner's Manual Supplement. Use recommended spark plugs with the proper gap. Use only resistor-type spark plugs. Torque spark plugs to 18-22 ft. lbs. (24
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 85
    Intake Filters 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. NOTICE: Operating the snowmobile with the intake filters removed may cause intake icing. The
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 86
    must be performed by an authorized Polaris dealer. Do not attempt to service the fuel pump. All fuel injector service must be performed by an authorized Polaris dealer. Do not attempt to clean or service the fuel injectors. Fuel Filter See your Polaris dealer for replacement of the fuel filter
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    completely before inspecting. 1. Open the hood and inspect the muffler and pipes for cracks or damage. 2. Check for weak or missing retaining springs or damper/support grommets. 3. Check for loose clamps on the pipe covers. 83
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 88
    MAINTENANCE Cooling System Coolant The coolant supplied in the system is a 60/40 mixture of ethylene-glycol and distilled water. This mixture provides protection against freezing. Contact your dealer if greater protection is required. Use Premium 60/40 anti-freeze coolant, which is already premixed
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 89
    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
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 90
    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.
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    Cooling System MAINTENANCE Bleeding the Cooling System Bleed the cooling system at the intervals outlined in the Periodic Maintenance Table beginning on page 72. Perform the bleeding procedure when the engine is cold. 1. Remove the pressure cap and fill the coolant bottle with properly mixed
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 92
    MAINTENANCE Drive Chain Tension Check drive chain tension weekly and before each long trip. 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.
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 93
    Brakes MAINTENANCE n Hydraulic Brake Inspection Inspect the brake lever travel before each use of the snowmobile. See page 51. Brake pads must be replaced when the brake pad material becomes thinner than the backing plate, approximately 1/16" (1.5mm). A kit is available for replacing brake pads.
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 94
    MAINTENANCE Brakes Brake Components Brake Disc Bleed Screw Brake Line Brake Caliper Brake Pad Material Replace when thickness is less than 1/16" (1.5mm). Bleed Screw Brake Disc Brake Line Brake Caliper Brake Pad Material Excessive Lever Travel Hydraulic brakes are selfadjusting, but if
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 95
    Brakes MAINTENANCE n Brake Fluid Replace brake fluid at least every two years with Polaris DOT 4 high temperature brake fluid. See page 110 for the part numbers of Polaris products. WARNING! After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 96
    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
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 97
    Lights MAINTENANCE Removing Halogen Bulbs Do not touch a halogen bulb with bare fingers. Oil from skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do touch the bulb, clean it with an alcohol-moistened towel. 1. Remove the plenum covBulb ering from the
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 98
    alignment offset is important for maintaining optimum performance. Please see your Polaris dealer if you experience a decrease in performance. Clutch Center Distance See your Owner's Manual Supplement for recommended center distance for your machine. If adjustment is necessary, see your dealer. 94
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 99
    O.E.M. belts be used. Other belts may match the dimensions, but can drastically change the shift pattern, resulting in poor performance. See Drive Belt Troubleshooting on page 115. Periodically check the condition and tension of the drive belt, and always carry a spare. Inspect the belt for signs of
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 100
    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. 1. Stop the engine after operating in a forward motion. TIP: For easier
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 101
    Clutch System MAINTENANCE Measure A Straight Edge 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 and apply downward pressure while measuring at point A. This measurement should be 1 1/4" (3.2 cm).
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 102
    , which could cause serious injury or death. Never operate with a damaged track. 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 to check for damage. 3. Carefully examine the track along the
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 103
    faster heat build-up in limited lubrication, resulting in excessive wear. WARNING! Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure, loss of vehicle control and loss of braking ability, which can result in serious injury or death. Avoid
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 104
    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
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 105
    Track Tension Adjusting Screw 10 lbs. (4.54 kg) Lock Nut MAINTENANCE Idler Shaft Bolt 16" (40 cm) If the track needs adjustment: 5. Loosen the rear idler shaft bolt. 6. Loosen the lock nuts. 7. Tighten or loosen the track adjusting screws as necessary to provide equal adjustment on both sides of
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 106
    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
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 107
    Steering System MAINTENANCE Steering Inspection and Adjustment Check all steering system fasteners weekly and before a long ride. Tighten any loose fasteners. + + + + + 103
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 108
    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
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 109
    any abnormal wear or chipping is found. Skag Replacement Some models are equipped with single skags. Other models are equipped with dual skags. 1. Raise and support the front of the snowmobile so the skis are approximately 6" (15 cm) from the ground. 2. Remove the attaching nuts and pry the skag
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 110
    MAINTENANCE Steering System n 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
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 111
    Matte Clear Coat Cleaning (if equipped) MAINTENANCE Matte finish products are prone to trapping dirt, oils and other contaminants. Polaris Industries recommends cleaning with warm water and a mild dish detergent. Use a soft sponge to gently rub the surface and rinse with clean warm water. For
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 112
    the driven clutch shaft bushing as outlined in the Master Repair Manual. See your dealer. Engine Protection Proper preparation of the engine days, the engine must be fogged with fogging oil. Follow the engine fogging instructions provided on the container. TIP: Do not spray fogging oil into the
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 113
    , moving parts, and hot exhaust parts. Track and Suspension Moderate track tension should be maintained during summer storage. The machine should be supported off the ground to allow the track to hang freely. Transporting the Snowmobile Whenever the snowmobile is transported: 1. Be sure the fuel
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 114
    POLARIS PRODUCTS Part No. 2870791 2877882 2877953 2877883 2877884 2877887 2877888 2873105 2872951 2871312 2871322 2871423 2871329 2871323 2871534 2871326 2870652 2872189 2872893 2870505 2872889 2872890 Description Engine Lubricants Fogging Oil (12 oz. Aerosol) VES Gold Plus Synthetic 2-Cycle Engine
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 115
    Engine Troubleshooting TROUBLESHOOTING Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Erratic engine operating RPM during acceleration or load variations Harsh drive clutch engagement Probable Cause Solution Drive clutch
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 116
    TROUBLESHOOTING Problem Noise in drive system Engine Troubleshooting Probable Cause Solution Broken drive clutch components Bearing failure/ chaincase, jackshaft, or front drive shaft Drive belt surface flat spots Drive chain loose Drive chain
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 117
    Engine Troubleshooting Problem Engine turns but fails to start Faulty ignition TROUBLESHOOTING Probable Cause Solution • Install new spark plug(s). If engine still fails to start, check for spark. If there's no spark, SEE YOUR DEALER. • Make sure
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 118
    TROUBLESHOOTING Problem Rear suspension bottoms too easily Rides too stiff in rear Suspension Troubleshooting Solution • Set static sag (see page 43). Adjust torsion spring blocks or install optional torsion springs to achieve correct sag dimensions. • Check for binding suspension
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 119
    Causes Driving at low RPM Insufficient warm-up TROUBLESHOOTING Belt Wear/Burn Diagnosis Solutions • Drive at higher RPM. Gear the machine down. Check belt deflection. • Warm the engine at least five minutes. Take the
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 120
    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
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 121
    snowmobiles in recovery of stolen machines. A. In addition to notifying the proper law enforcement officials, the owner must call Polaris Customer Service. B. Owners must provide their name, address, telephone number and the model and serial number of stolen machines. 2. Polaris warranty will
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 122
    and set-up of your snowmobile is very important in ensuring trouble-free operation. Purchasing a snowmobile in the crate or without proper 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
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 123
    dealer is YOUR responsibility). Polaris recommends that you use your original selling dealer; however, you may use any Polaris Servicing Dealer to perform warranty service. Please work with your dealer to resolve any warranty issues. Your dealer will contact the appropriate personnel at Polaris if
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 124
    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
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 125
    oil. • Piston seizures, unless caused by a defective engine component. • Failures caused due to improper adjustments. • Failure due to unauthorized service. • Failures due to lack of service as required in the owner's manual or Polaris updates. This includes off-season storage as listed in the owner
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 126
    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
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 127
    U.S.A. EPA Emissions Limited Warranty 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
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 128
    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
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 129
    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
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 130
    MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 126
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 131
    MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 127
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 132
    Adjustment...97 Drive Belt Condition ...95 Drive Belt Deflection...97 Drive Belt Installation ...95 Drive Belt Removal ...96 Drive Belt Troubleshooting ...115 G Gauge Cleaning ...38 H Handlebar Adjustments ...46-47 Handlebar Angle ...47 Handlebar Position ...47 Headlight Adjustments ...28 Helmet
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 133
    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
  • 2010 Polaris 800 RMK Assault | Owners Manual - Page 134
    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 114 130
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