2005 Polaris TRAIL RMK, 600 RMK, 700 RMK, 800 RMK, 900 RMK, 600 SWITCHBACK, and 800 SWITCHBACK Deep Snow Service Manual (P/N 9919302)

The 2005 Polaris Deep Snow Service Manual (P/N 9919302, copyright 2004) covers TRAIL RMK, 600 RMK, 700 RMK, 800 RMK, 900 RMK, 600 SWITCHBACK and 800 SWITCHBACK snowmobiles, with model-specific specifications and procedures across 14 service chapters.

PDF Search and Wiring-Sheet Navigation

Search and diagram detail: Service chapters contain searchable text, and embedded bookmarks provide chapter and procedure navigation. Wiring-sheet labels are not searchable; rotate the sheets and zoom in to read small connector IDs and wire codes.

One printable English PDF contains 308 pages, including two cover pages, two safety/foreword pages, 13 notes pages and the wiring-section divider.

Engine, Clutch and Deep-Snow Chassis Service

Selected coverage is outlined below; other topics include recoil-starter service and off-season storage preparation.

• Engine repair: Engine removal, crankcase disassembly, piston and cylinder inspection, crankshaft indexing and truing, reed-valve checks, and engine-specific assembly procedures.

• Fuel delivery: Mikuni carburetor overhaul and synchronization, altitude/temperature jetting charts, ACCS operation, and separate 900 Liberty injection and TPS procedures.

• Clutching: P-85 drive-clutch inspection and assembly, spider indexing, TEAM driven-clutch service, belt-wear diagnosis, deflection adjustment, and clutch alignment.

• Final drive and brakes: Chaincase bearing replacement, jackshaft and driveshaft service, hydraulic bleeding, brake-pad replacement, and Hayes master-cylinder cartridge service.

• Steering and suspension: EDGE and IQ alignment, spindle and control-arm replacement, rear-suspension setup, shock-valving specifications, and Ryde FX rebuilding.

• Electrical diagnosis: Ignition and starting-system tests, 900 Liberty sensor checks, ECU connector pinouts, Digital Wrench connections, and model-specific wiring diagrams.

Written primarily for certified Polaris snowmobile service technicians working in a properly equipped shop, this manual assumes knowledge of mechanical theory, tool use and shop procedures.

Engine Inspection and Assembly References

The engine chapter separates EC55, small-block Liberty, 700/800 Liberty and 900 Liberty procedures. Cylinder-head, cylinder-base, crankcase and flywheel torque tables are supported by engine-specific tightening patterns.

Factory tolerances provide a workbench reference for assessing component condition and checking assembly. The general-information chapter adds piston-wash illustrations, bearing inspections and crankshaft truing with alignment kit P/N 2870569, connecting measurements with the related repair work.

Oil- and water-pump procedures distinguish the small-block cross shaft, the belt-driven 700/800 arrangement and the 900 cross-shaft assembly. Cooling-system bleeding and exhaust-valve maintenance have separate coverage for the applicable engine designs.

Carburetors and 900 Liberty Injection

The Mikuni TM 38/40 exploded view accompanies disassembly, cleaning, needle-and-seat testing and reassembly. Troubleshooting is organized by throttle opening, while the specification charts distinguish carbureted models and operating conditions.

The 900 Liberty material covers fuel-rail pressure relief, pump checks, injector identification and TPS baseline setting. Injector replacement is tied to the ECU’s color coding.

The in-tank 900 fuel pump is described as non-serviceable; the specified replacement is the complete fuel-tank assembly.

Clutch Setup and Belt Diagnosis

The Polaris P-85 exploded view supports inspection of sheaves, rollers, bushings and flyweights. Spring, weight and helix data accompany belt diagnosis, offset checks and alignment procedures.

Incorrect sheave indexing or misplaced spider shims can upset clutch balance and require clutch replacement. The manual reserves drive-clutch repair for appropriately trained, authorized Polaris service technicians using factory-authorized tools.

Suspension, Steering and Chassis

Alignment coverage distinguishes RMK, Switchback and IQ setups, including camber, setup width and toe measurements. Rear-suspension sections explain limiter straps, torsion springs, scissor stops and their effects on weight transfer.

The Typical Shock Valving Arrangement shows piston orientation and compression/rebound stacks. Illustrated rebuilding procedures cover Ryde FX gas-charged IFP and emulsion mono-tube shocks; Fox coverage includes special-tool listings. Improper clamping can deform the Ryde FX shock-body cylinder.

Chassis coverage includes hood, console, seat and fuel-tank removal, plus nosepan replacement. The hood section distinguishes replacement of damaged TPO hoods from stop-drilling small cracks.

Electrical Fault Finding and Wiring

The “Condition: No Spark” diagnostic chart complements ignition-timing, charging and starter tests. Separate 900 Liberty sections address DET operation, temperature and crank-position sensors, ECU connections and the Digital Wrench diagnostic and power-up ports.

Wiring sheets cover the carbureted models and the 900 RMK hood and chassis harnesses. Secure the snowmobile, keep clear of rotating drivetrain parts and follow the manual’s electrical-isolation precautions during service.

Examples of Inspection Specifications

For 700/800 Liberty water-pump-belt inspection, the manual lists a nominal new width of .345" (8.75 mm) and replacement below .250" (6.35 mm).

The reed-valve inspection section specifies a maximum .015" (.38 mm) gap between the fiber reed and reed block.