2005 Polaris TRAIL RMK, 600 RMK, 700 RMK, 800 RMK, 900 RMK, 600 SWITCHBACK, and 800 SWITCHBACK Deep Snow Service Manual (P/N 9919302)
308 Pages • 22.02 MB • Instant, Printable PDF
Polaris Models Covered & Key Technical Specifications
Models: TRAIL RMK, 600 RMK, 700 RMK, 800 RMK, 900 RMK, 600 SWITCHBACK, 800 SWITCHBACK
Sub-models / Variants: 600 RMK 144, 800 SWITCHBACK
Model Years: 2005
Serial Numbers: S05NJ5BS(A), S05NK6ES(A), S05N(K,L)7CS(A), S05N(M,K,L)8CS(A,B), S05P(L,M)8DS(A,B,C,D), S05NS6ES(A), S05NSCS(A)
Technical Data:
- Engine displacement: 544 cc (Trail RMK), 599 cc (600 RMK/Switchback), 701 cc (700 RMK), 794 cc (800 RMK/Switchback), 866 cc (900 RMK)
- Engine configuration: Liberty 2-cylinder, liquid-cooled (except 544cc fan-cooled Trail RMK)
- Carburetion: Mikuni VM34SS (Trail RMK), Mikuni TM38 (600 RMK/Switchback), Mikuni TM40 (700/800 RMK/Switchback)
- Fuel system (900 RMK): Clean Fire Injection, 4 Bar (58 psi) regulator pressure
- Drive clutch: P-85
- Suspension type: EDGE RMK, IQ (900 RMK)
- Spark plug (NGK): BR9ES (.028" gap)
- Spark plug (Champion): RN57YCC (.025" or .028" gap)
- Coolant capacity: 5 qts / 4.7 L (most models), 6.7-6.9 qts / 6.3-6.4 L (900 RMK)
Polaris Manual Features & Content Preview
- Covers the 2005 Polaris TRAIL RMK, 600 RMK, 700 RMK, 800 RMK, 900 RMK, 600 SWITCHBACK, and 800 SWITCHBACK, detailing engine, chassis, and suspension configurations
- Official Polaris OEM publication (P/N 9919302, copyright 2004) covering comprehensive review and repair data
- Contains 47 exploded-view diagrams, 15+ wiring schematics, and 12+ critical-component torque tables
- Features altitude-based jetting charts for all listed models and complete 900 Liberty Clean Fire Injection diagnostic procedures
Manual Content Overview
This 308-page factory reference delivers the exact specifications required for certified technician-level servicing of the 2005 Deep Snow lineup. It organizes technical data into 14 distinct chapters, giving mechanics direct access to everything from fuel delivery systems and clutching to final drive, braking, and steering. The document clearly maps out maintenance programs for the Liberty 544, 600, 700, 800, and 900 powerplants. You will also find front and rear suspension adjustments detailed alongside precise chassis and hood system layouts.
Working on snowmobiles carries inherent risks; always verify that the machine is properly secured and battery leads are disconnected before initiating any electrical or mechanical repair. The electrical sections provide comprehensive wiring diagrams for every model configuration to support safe diagnostics. Critical engine component torque values are fully documented to ensure correct assembly. For example, crankshaft runout for Liberty engines is strictly specified at .000"–.00015" (.04mm). The cooling system capacity for the 900 RMK sits at 6.7–6.9 quarts. If you are looking up ignition details, the spark plug gap for the Champion RN57YCC requires exactly .025" (.64mm) for specific builds. Additionally, throttle body TPS voltage at idle must read .92–.94 VDC for the 900 Liberty fuel injection system. These definitive service thresholds are essential for maintaining peak performance out on the snow.
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