Polaris 2005 Deep Snow Service Manual (TRAIL RMK, 600 RMK, 700 RMK, 800 RMK, 900 RMK, 600 SWITCHBACK™, 800 SWITCHBACK™) – Comprehensive Snowmobile Service Guide 2005
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Sample pages from the Polaris 2005 Deep Snow Service Manual (TRAIL RMK, 600 RMK, 700 RMK, 800 RMK, 900 RMK, 600 SWITCHBACK™, 800 SWITCHBACK™) – Comprehensive Snowmobile Service Guide 2005 manual
Purchase Information
2005 Polaris Deep Snow Service Manual: RMK & Switchback Models - Technical Specifications
- Document Number / Seller:
- 32140 / Ronald Thompson
- File Size:
- 22.02 MB
- File Type:
- Language:
- English
- Pages:
- 308
- Printable:
- Yes
- Estimated Download Time:
- 0.45 Minutes
- Delivery Format:
- Digital (PDF) - Instant Access
- Category:
- Snowmobile
- Brand:
- Polaris
- Reviewed and Approved:
- Jan 1, 2026
Polaris Models and Parts Covered in this Snowmobile Manual
- Polaris TRAIL RMK (2005)
- Polaris 600 RMK (2005)
- Polaris 700 RMK (2005)
- Polaris 800 RMK (2005)
- Polaris 900 RMK (2005)
- Polaris 600 SWITCHBACK™ (2005)
- Polaris 800 SWITCHBACK™ (2005)
- Polaris 600 RMK 144" (2005)
- Polaris 700 RMK 144" (2005)
- Polaris 700 RMK 151" (2005)
- Polaris 800 RMK 144" (2005)
- Polaris 800 RMK 151" (2005)
- Polaris 800 RMK 159" (2005)
- Polaris 900 RMK 151" (2005)
- Polaris 900 RMK 159" (2005)
- Polaris 900 RMK 166" (2005)
Complete Manual Information
Polaris Deep Snow Snowmobile Service Manual - 2005 Edition
This professional Service Manual provides the definitive technical framework for maintaining and repairing Polaris high-performance deep snow snowmobiles. It delivers high-fidelity factory specifications and procedural depth to ensure maximum machine reliability and performance in extreme alpine environments. A critical factor for operational uptime is the precision maintenance of the water pump drive belt on Liberty engines, which must be replaced if the width falls below .25 inches to prevent catastrophic thermal failure.
Technical Applicability & Chassis Configurations
To ensure precise utility, this manual categorizes technical data based on chassis architecture and engine displacement, allowing for exact calibration and parts synchronization.
IQ Chassis / Liberty 900 Engine Platform
- 900 RMK (2005): Equipped with Clean Fire Injection and the IQ front suspension system, featuring AFX standard shocks or Arvin IFP premium options.
EDGE Chassis / Liberty Twin Engine Platform
- 600 / 700 / 800 RMK (2005): Deep snow specialized models utilizing the EDGE RMK rear suspension with 144", 151", or 159" track lengths.
- 600 / 800 SWITCHBACK™ (2005): Hybrid crossover configurations featuring the EDGE 144" rear suspension and coupled front IFS for varied terrain.
Standard Chassis / Fan-Cooled Series
- TRAIL RMK (2005): Utilizing the 544cc Fuji engine (EC55) paired with a VM34SS carburetion system and ACCS for altitude compensation.
Operational Parameters & Maintenance ROI
- System Calibration: Factory-defined jetting charts and clutch offset parameters eliminate operational inefficiencies and maximize horsepower delivery across varying altitudes.
- Safety & Integrity: Verified torque sequences and standard fastener specifications prevent component stress fractures and ensure the structural integrity of steering and suspension assemblies.
- Diagnostic Accuracy: Detailed electrical schematics and resistance values facilitate rapid troubleshooting of ignition and Clean Fire Injection systems, reducing diagnostic labor time.
Document Metadata
- Print No: 9919302
- Total Pages: 307
- Primary Focus: Deep Snow / Alpine Service Operations
Technical Depth & Factory Benchmarks
Mechanical integrity is maintained through rigorous adherence to factory-established tolerances and calibration benchmarks.
- Cylinder Geometry: Service limits for cylinder head warp are strictly capped at .003" (0.08mm) to ensure combustion chamber sealing.
- Crankshaft Indexing: Multi-cylinder crankshafts are indexed to a 180° tolerance (±2°) to minimize harmonic vibration and prevent premature bearing fatigue.
- Fuel Metering: Precise Mikuni TM and VM carburetor configurations are provided, including pilot jetting, needle tapers, and main jet sizing for ambient temperatures ranging from -30°F to above +50°F.
Visual Navigation Aids
Strategic use of technical illustrations and diagrams assists in the correct execution of complex mechanical tasks.
- Exploded View Architecture: Comprehensive breakdowns of the P-85 Drive Clutch and TEAM Driven Clutch systems clarify assembly order and shim placement.
- Cooling Circuitry: Detailed flow diagrams for the 900 Fusion and RMK cooling systems highlight bleed screw locations and crossover hose routing for effective thermal management.
- Electrical Logic: Full-scale wiring diagrams identify connector pinouts and ground locations critical for the 900 Liberty electrical system.
Table of Contents: Detailed Primary Sections
- Specifications: Model-specific engine, carburetion, and clutching data.
- General Information: VIN decoding, standard torque values, and crankshaft truing.
- Maintenance: Periodic service charts, lubrication points, and track tensioning.
- Engine: Complete disassembly and assembly for 550, 600, 700, 800, and 900 series.
- Fuel Delivery: Carburetor synchronization and Clean Fire Injection parameters.
- Clutching: CVT operation, spring rates, and belt deflection adjustments.
- Suspension: Front (IFS/IQ) and Rear (EDGE/IQ) setup and shock valving.
- Electrical: Timing procedures, stator testing, and wiring schematics.
Operational Limits & Torque Specifications
Engine and drivetrain components require exact force application to maintain service life under high-load conditions.
| Component | Torque Specification (ft. lbs.) | Lubricant/Agent |
|---|---|---|
| Cylinder Head Bolts (Liberty) | 22 ft. lbs. (±2) | Loctite 242 |
| Crankcase Bolts (10mm) | 28 ft. lbs. (±2) | Loctite 242 |
| Flywheel Nut | 90 ft. lbs. (±10) | Loctite 242 |
| Drive Clutch Bolt | 50 ft. lbs. (nominal) | Non-lubricated |
| Spark Plugs | 12 - 14 ft. lbs. | Anti-Seize |
| Brake Fluid Type | DOT 3 (Standard) / DOT 4 (900) | Polaris Specified |
Download Instructions for Polaris Snowmobile Manual
Frequently Asked Questions - Polaris Snowmobile Manual
What does this Polaris manual cover?
This comprehensive service manual covers detailed repair procedures, maintenance schedules, troubleshooting guides, and technical specifications for Polaris 2005 Deep Snow Service Manual (TRAIL RMK, 600 RMK, 700 RMK, 800 RMK, 900 RMK, 600 SWITCHBACK™, 800 SWITCHBACK™) – Comprehensive Snowmobile Service Guide 2005. It includes information for the following models: - Polaris TRAIL RMK (2005) - Polaris 600 RMK (2005) - Polaris 700 RMK (2005) - Polaris 800 RMK (2005) - Polaris 900 RMK (2005) - Polaris 600 SWITCHBACK™ (2005) - Polaris 800 SWITCHBACK™ (2005) - Polaris 600 RMK 144" (2005) - Polaris 700 RMK 144" (2005) - Polaris 700 RMK 151" (2005) - Polaris 800 RMK 144" (2005) - Polaris 800 RMK 151" (2005) - Polaris 800 RMK 159" (2005) - Polaris 900 RMK 151" (2005) - Polaris 900 RMK 159" (2005) - Polaris 900 RMK 166" (2005).
Is this manual suitable for beginners?
Yes, this Polaris manual is designed for both professional technicians and DIY enthusiasts. It includes step-by-step procedures with clear illustrations and safety guidelines for Snowmobile maintenance and repair.
What file format will I receive?
You will receive this manual as a PDF file (22.02 MB), which is compatible with all devices. The manual is fully searchable and printable for your convenience.
How quickly can I access the manual after purchase?
You'll receive instant access to your Polaris Snowmobile manual immediately after payment completion. The download link is valid for 3 days, with lifetime re-download guarantee.
Can I print specific sections of the manual?
Absolutely! This digital manual allows you to print any section you need, from individual pages to complete chapters, making it perfect for workshop use.
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