2004 Polaris RMK & Switchback Snowmobile Service Manual
Official service manual for 2004 Polaris Trail RMK, 600 RMK, 700 RMK, 800 RMK, 600 Switchback, 700 Switchback, and 800 Switchback snowmobiles. PN 9918587.
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Models Covered & Key Technical Specifications
2004 Polaris RMK & Switchback Snowmobile Service Manual
This manual provides comprehensive service and repair information for the 2004 Polaris RMK and Switchback series snowmobiles. Models Covered: Trail RMK, 600 RMK, 700 RMK, 800 RMK, 600 Switchback, 700 Switchback, 800 Switchback. Part Number: 9918587
- Engine Specifications: Features detailed engine data for the Liberty engines used across the RMK and Switchback models.
- Clutch System Maintenance: Outlines procedures for drive and driven clutch inspection, adjustment, and maintenance for optimal performance.
- Suspension Alignment: Provides precise specifications for front suspension setup, including width, camber, and toe alignment.
- Carburetor Tuning: Details the Mikuni TM carburetor system, including jetting guidelines and troubleshooting for optimal fuel mixture.
- Drive Belt Service: Covers drive belt inspection, diagnosis of wear or burning, and belt deflection adjustments for proper operation.
- Electrical System Components: Lists key electrical components and their specifications for maintenance and troubleshooting.
Professional Workshop Service Manual & Technical Specifications
Complete Operations Manual: Polaris TRAIL RMK, 600 RMK 144", 700 RMK 144"/151", 800 RMK 144"/151"/159", 600/700/800 SWITCHBACK Snowmobiles Service Manual (2004) Hydraulic-Guide
Architecture-Focus: Engine assemblies, suspension systems, and drive train components Logic // Performance-Values: Carburetor tuning, clutch calibration, and belt specifications // Diagnostic-Area: Troubleshooting guides for common engine and chassis issues.
| Service-Nexus | Rating | Calibration-Data |
|---|---|---|
| Engine Disassembly | 550 EC 34 / 55 | 3.19 – 3.36 |
| Clutch Weights | P-85 / TEAM | 5.2 – 5.3 |
| Steering Alignment | EDGE RMK | 6.2 |
| Carburetor Synchronization | Mikuni TM | 4.20 |
| Drive Belt Inspection | All Models | 5.31 |
Technical content addresses the complete service and repair needs for the specified Polaris snowmobile models. Rigorous procedures ensure optimal function and longevity of the machine.
Engine Maintenance
Covers engine disassembly, assembly, and troubleshooting for Liberty engines, including specific procedures for EC34/55, and 700/800 series. Details include torque specifications, piston inspection, cylinder honing, and crankshaft maintenance.
Clutch System Service
Provides detailed information on drive and driven clutch maintenance, including disassembly, inspection, spider indexing, and spring selection. Covers P-85 and TEAM roller clutches.
Steering and Suspension
Details front suspension alignment specifications for various models, including camber, toe, and width adjustments. Covers ski installation, torsion bar removal, and handlebar adjustment.
Fuel and Carburetion System
Explains the Mikuni TM carburetor system, including jet part numbers, pilot and main jet functions, and troubleshooting tips for mixture issues. Covers float level adjustment and throttle synchronization.
Troubleshooting
Offers solutions for common problems such as starting issues, poor fuel mileage, engine overheating, and clutch malfunctions. Provides a systematic approach to diagnosing and resolving mechanical problems.
This manual documents torque specifications for various components to ensure proper structural integrity and prevent damage.
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