Comprehensive Service & Repair: Polaris TRAIL RMK, 600 RMK 144", 700 RMK 144"/151", 800 RMK 144"/151"/159", 600/700/800 SWITCHBACK Snowmobiles Service Manual (2004)
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Sample pages from the Comprehensive Service & Repair: Polaris TRAIL RMK, 600 RMK 144", 700 RMK 144"/151", 800 RMK 144"/151"/159", 600/700/800 SWITCHBACK Snowmobiles Service Manual (2004) manual
Purchase Information
Technical Specifications
- Document Number / Seller:
- 32200 / Dorothy Allen
- File Size:
- 22.68 MB
- File Type:
- Language:
- Pages:
- 294
- Printable:
- Yes
- Estimated Download Time:
- 0.46 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 (2004)
- Polaris 600 RMK (2004)
- Polaris 600 SWITCHBACK (2004)
- Polaris 700 RMK (2004)
- Polaris 700 SWITCHBACK (2004)
- Polaris 800 RMK (2004)
- Polaris 800 SWITCHBACK (2004)
- Polaris 600 RMK 144" (2004)
- Polaris 700 RMK 144" (2004)
- Polaris 700 RMK 151" (2004)
- Polaris 800 RMK 144" (2004)
- Polaris 800 RMK 151" (2004)
- Polaris 800 RMK 159" (2004)
Complete Manual Information
Polaris Deep Snow Series Service Manual - 2004 Edition
This professional workshop publication provides the authoritative framework for maintaining and repairing the high-performance 2004 Polaris mountain and crossover snowmobile lineup. Engine reliability is maximized through the precise monitoring of the water pump belt, which must be replaced if the nominal width of 0.345" (8.75mm) degrades to less than 0.250" (6.35mm). This hyper-specific measurement is critical for preventing catastrophic cooling system failure and ensuring maximum engine uptime in extreme deep snow conditions.
Technical Applicability & Model Configurations
Edge Chassis Series - Mountain (RMK)
- Polaris Trail RMK: 544cc Fuji Air-Cooled (Model S04NJ5BS)
- Polaris 600 RMK 144": 599cc Liberty VES Liquid-Cooled (Model S04NK6ES)
- Polaris 700 RMK 144" / 151": 701cc Liberty VES Liquid-Cooled (Models S04NK7CS, S04NL7CS)
- Polaris 800 RMK 144" / 151" / 159": 794cc Liberty VES Liquid-Cooled (Models S04NK8CS, S04NL8CS, S04NM8CS)
Edge Chassis Series - Crossover (Switchback)
- Polaris 600 Switchback: 599cc Liberty VES Liquid-Cooled (Model S04NS6ES)
- Polaris 700 Switchback: 701cc Liberty VES Liquid-Cooled (Model S04NS7CS)
- Polaris 800 Switchback: 794cc Liberty VES Liquid-Cooled (Model S04NS8CS)
Operational Parameters & Service ROI
- System Accuracy: Includes detailed jetting charts for Mikuni VM and TM carburetors across all altitude and temperature variables to prevent lean-burn piston damage.
- Safety Protocols: Standardized torque sequences for cylinder heads and crankcases ensure structural integrity under high thermal stress.
- Component Longevity: Specific grease point mapping for the Edge RMK and rear suspensions prevents premature pivot shaft wear.
Document Metadata
- Publication Number: PN 9918587
- Total Content: 11 Detailed Chapters
- Format: Professional Service Manual
Technical Depth & Factory Benchmarks
Engine Calibration Data
- Cylinder Head Torque (Liberty 600/700/800): 18-22 ft. lbs. (25-30 Nm) applied in factory-specified sequences.
- Cylinder Base Nut Torque (Liberty): 30-34 ft. lbs. (42-47 Nm).
- Ignition Timing (800 RMK): 29° @ 3250 RPM with TPS disconnected.
- Piston-to-Cylinder Clearance (700 RMK): 0.0044" - 0.0058" (0.112 - 0.147mm).
Visual Navigation Aids
- Clutch Architecture: Exploded views of the P-85 Drive Clutch and Team Roller Driven Clutch for precise shimming and spider indexing.
- Electrical Schematics: Full-page wiring diagrams covering CDI ignition, lighting circuits, and electronic reverse (PERC) systems.
- Fluid Circuit Mapping: Cooling system flow diagrams and oil injection line routing to ensure air-free lubrication.
Table of Contents
- Chapter 1: General Information (Specs, VIN, Torque)
- Chapter 2: Maintenance (Lubrication, Adjustments, Tune-ups)
- Chapter 3: Engine (Liberty & Fuji Service, VES Maintenance)
- Chapter 4: Fuel Delivery (Mikuni TM/VM Carburetion, Fuel Pumps)
- Chapter 5: Clutching (PVT System, P-85 and Team Roller Service)
- Chapter 6: Body & Steering (Alignment, Plastic Repair)
- Chapter 7: Suspensions (Edge RMK, Shock Rebuilding)
- Chapter 8: Final Drive (Chaincase, Gearing, Brakes)
- Chapter 9: Electrical (CDI, Stators, Troubleshooting)
- Chapter 10: Wiring Diagrams
- Chapter 11: Index
Operational Limits & Specifications
- Chaincase Lubricant: 11 fl. oz. (325 cc's) of Polaris Synthetic Chaincase Lubricant.
- Track Tensioning: 10 lb. weight applied 16" ahead of idler shaft; 3/8" - 1/2" (1-1.3 cm) deflection required for RMK models.
- Spark Plug Gap: 0.028" (0.70mm) for both NGK and Champion specified resistors.
- Brake Fluid: Polaris DOT 3 High Temperature Fluid only; maintain level 1/4" - 5/16" below reservoir lip.
Download Instructions for Polaris Snowmobile Manual
Frequently Asked Questions - Polaris Snowmobile Manual
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 (22.68 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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