Snowmobile Polaris 600 RMK / 600 PRO RMK / 800 RMK / 800 PRO RMK / 800 RMK Assault. Manual - part 23

MAINTENANCE

Brakes

Hydraulic Brake Inspection

Inspect the brake lever reserve before each use of the snowmobile. See
page 59.

Brake pads must be replaced when the brake pad material becomes thin-
ner than the backing plate (approximately 1/16 inch or 1.5 mm). A kit is
available for replacing brake pads. See your dealer.

WARNING! Brake failure during operation can result in serious injury or death.
Properly functioning brakes are vital to your safety. Be sure the brake pads do
not drag on the disc and that brake lever travel is not excessive. Always replace
brake pads when the brake pad material becomes thinner than the backing plate
(approximately 1/16 inch or 1.5 mm).

Brake Components

1. Brake Caliper

2. Brake Disc

3. Brake Pad Material (Replace

when thickness is less than
1/16 inch or 1.5 mm).

4. Anti-rattle springs (come

with brake pad kit)

Excessive Lever Travel

Hydraulic brakes are self-adjust-
ing, but if excessive brake pad
clearance develops, bring the
snowmobile to an authorized
POLARIS dealer for inspection
and adjustment.

TIP: The PRO RMK and RMK ASSAULT models are equipped with a lightweight

brake disc that has vent holes. These holes may cause a high-pitched
sound during operation.

MAINTENANCE

Brakes

Brake Fluid

The brake fluid level can be seen through a plastic sight glass in the
brake reservoir. If the fluid is sufficient, the sight glass will be black. If
the sight glass is any color other than black, add brake fluid.

Replace brake fluid at least every two years with POLARIS DOT 4 high
temperature brake fluid. See page 116 for the part numbers of POLARIS
products.

WARNING! After opening a bottle of brake fluid, always discard any unused
portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it
rapidly absorbs moisture from the air. The moisture causes the boiling
temperature of the brake fluid to drop, which can lead to early brake fade and
the possibility of accident or serious injury.

WARNING! Keep the master cylinder cover free of dirt and debris. The vent slits
allow for diaphragm movement, and if they become plugged, movement of
brake fluid below the diaphragm may be restricted, altering brake function.

NOTICE: Brake fluid will damage labels, paint and some plastics. Always wipe

up spills immediately.

MAINTENANCE

Brakes

Bleeding the Hydraulic Brake System

Air in the hydraulic brake system will cause spongy brake lever action.
Bleed the system before operating the snowmobile.

WARNING! Operating the vehicle with a spongy brake lever can result in loss of
brakes, which could cause an accident and lead to serious injury or death.
Never operate the vehicle with a spongy-feeling brake lever.

During the bleeding procedure, keep the brake handle as level as possi-
ble. The reservoir must be in this position to minimize the possibility of
air entering the system through the reservoir vent.

1. Remove the brake master cylinder reservoir cover and gasket.

2. Fill the master cylinder reservoir to between the MIN and MAX

marks or 1/4-5/16 inch (.6-.8 cm) below the lip of the reservoir
opening. Reinstall the gasket and cover.

3. Slip a rubber tube over the ball of the bleeder valve and direct the

flow of fluid into an approved container.

4. Squeeze the brake lever a full stroke. Then unscrew the bleeder

valve 3/4 of a turn to release air.

5. Close the bleeder valve and release the brake lever.

6. Repeat steps 4 and 5 until fluid flows from the bleeder valve in a

solid stream free of air bubbles.

WARNING! Overfilling the master cylinder leaves no room for fluid expansion
and may cause the brakes to lock, resulting in serious injury or death. Always
add brake fluid to the fill line as recommended.

7. After bleeding is complete, refill the reservoir to the proper level.

See page 95.

8. Reinstall the gasket and cover.

MAINTENANCE

Lights

When servicing a halogen lamp, avoid touching the lamp with bare fin-
gers. Oil from your skin leaves a residue, causing a hot spot that will
shorten the life of the lamp. If fingers do touch a lamp, clean it with
denatured alcohol.

Headlight Lamp Replacement

1. Peel back the foam shield covering the headlight assembly.

2. Remove the wire harness connector from the back of the headlight.

3. Grasp the bulb housing and turn it counter-clockwise to remove the

bulb.

4. Apply dielectric grease to the socket and install the new bulb.

Rotate the bulb 1/4 turn clockwise to secure it.

5. Reinstall the connector to the back of the headlight.

6. Secure the foam shield.

Taillight/Brake Light Replacement

The taillight assembly is not serviceable. If the light fails to operate
properly, replace the entire taillight assembly.

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