2004 Polaris Trail RMK, 600 RMK, 700 RMK, 800 RMK, 600 Switchback, 700 Switchback, 800 Switchback Snowmobile Service Manual (P/N 9918587)

This 294-page PDF is the Polaris factory Deep Snow service manual, P/N 9918587, for the 2004 Trail RMK, 600/700/800 RMK, and 600/700/800 Switchback. Coverage is keyed to model numbers S04NJ5BS, S04NK6ES, S04NK7CS, S04NL7CS, S04NK8CS, S04NL8CS, S04NM8CS, S04NS6ES, S04NS7CS, and S04NS8CS. Its internal-engine, clutch, brake, electrical, and gas-shock repair depth is suited to experienced snowmobile technicians and well-equipped owners who already understand precision inspection and assembly; Polaris specifically limits drive-clutch disassembly and repair to trained authorized dealers.

• Engine repair: Covers removal and recoil service; EC55 fan-cooled engine overhaul; 600 Liberty small-block and 700/800 Liberty disassembly, inspection, and reassembly; piston, cylinder, crankcase, bearing, crankshaft truing and indexing work; oil-pump bleeding and adjustment; liquid-cooling service; and V.E.S. cleaning and inspection.
• Fuel delivery: Details Mikuni VM and TM carburetor operation, disassembly, inspection, assembly, float setting, throttle synchronization, choke adjustment, fuel-pump checks, altitude/temperature jetting charts, component-effect charts, and throttle-range troubleshooting.
• PVT clutching: Includes P-85 drive-clutch and Team roller driven-clutch removal, internal inspection, spider roller service, button shimming and indexing, driven-clutch teardown, belt diagnosis and deflection, clutch offset/alignment, belt-to-sheave clearance, and fault charts.
• Steering and body: Provides IFS inspection, steering alignment, camber and toe adjustment, radius-rod and tie-rod procedures, ski-spindle bushing replacement, steering-arm orientation, ski installation, torsion-bar service, and handlebar torque sequence.
• Suspension service: Covers EDGE RMK setup, limiter-strap and torsion-spring adjustment, Hi-Fax replacement, IFS/front/rear track shock specifications, valving data, Ryde FX shock rebuilding, and suspension troubleshooting.
• Brakes and final drive: Walks through hydraulic brake bleeding, Hayes master-cylinder repair, pad replacement, rear-suspension removal, chaincase inspection, jackshaft and driveshaft service, track installation, and final drive reassembly.
• Electrical diagnosis: Includes multimeter use, ignition timing, D.E.T. operation and flash-code troubleshooting, battery and starting-system tests, starter and solenoid service, charging-output checks, switch tests, and no-spark/incorrect-timing fault isolation.

Configuration Detail

The specification sheets separate the 136-inch Trail RMK with the EC55PM070 544 cc fan-cooled Liberty from the liquid-cooled 600, 700, and 800 platforms. Track coverage includes the 144-inch 600 RMK, 144/151-inch 700 RMK, 144/151/159-inch 800 RMK, and 144-inch Switchback models. Carburetion is also application-specific: VM34SS with ACCS on the Trail RMK, TM38 on 600 models, TM40 on the RMK 700/800 and 800 Switchback, and VM40 on the 700 Switchback. These distinctions matter when selecting jetting, clutch calibration, ignition data, and cooling procedures.

Workshop Reference Content

Routine service information covers filters and the sediment trap, chaincase oil and drive-chain adjustment, 700/800 water-pump belt tension, track inspection and alignment, PVT belt care, hydraulic-brake inspection, throttle free play, and seasonal storage.

Named visuals include the 600/700/800 RMK/Switchback cooling-system routing diagram, Mikuni VM30/34SS and TM38/TM40 exploded views, P-85 drive-clutch and driven-clutch exploded views, the typical shock-valving stack, and the two model-group electrical schematics: one for the Trail RMK group and one for domestic electric-reverse 600/700/800 RMK and Switchback models.

Factory tool references identify the P-85 offset-alignment tool 2870426, 550 drive-clutch puller 2872084, domestic-engine drive-clutch puller 2872085, clutch spider removal/installation tool 2870341, gas-shock recharging kit 2200421, and Ryde FX IFP positioning/extraction tool PS-45261. Specifications include component torque tables, tightening-sequence diagrams for EC55 and Liberty engines, clearances, wear limits, jetting data, clutch and suspension setup data, brake checks, and electrical test values.

Repair Cautions and Scope

The clutch chapter warns that failing to mark the P-85 sheaves and spider, or misplacing the spider shims, can leave the assembly out of balance and require clutch replacement. During gas-shock repair, clamping the unit anywhere other than the lower mount can deform the shock-body cylinder. The manual also flags hazards from hot coolant, gasoline, spring-loaded clutch parts, moving tracks, hydraulic brakes, and pressurized nitrogen shocks.

This Deep Snow volume does not cover the 2004 PRO X, XC SP, Touring, Frontier, Trail Sport, or Trail Luxury families; Polaris assigns those machines to separate service manuals. Parts manuals and microfiche are listed separately, so this publication should not be purchased as a full illustrated parts catalog.