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Snowmobile Polaris DEEP SNOW (2005 year). Manual - part 6

GENERAL INFORMATION

2.3

PUBLICATION PART NUMBERS

Model

Model No.

Owner’s Manual

Owners Manual

Supplement

Parts

Manual

Microfiche

Trail RMK

S05NJ5BS(A)

9919706

9919097

9919276

9919277

600 RMK

S05NK6ES(A)

9919706

9919098

9919278

9919279

700 RMK

S05N(K,L)7CS(A)

9919706

9919381

9919278

9919279

800 RMK

S05N(M,K,L)8CS(A,B)

9919706

9919383 (144)
9919384 (151)
9919385 (159)

9919278

9919279

900 RMK

S05P(L,M)8DS(A,B,C,D)

9919077

9919104 (151)
9919105 (159)
9919106 (166)

9919292

9919293

600 Switchback

S05NS6ES(A)

9919076

9919095

9919280

9919281

800 Switchback

S05NSCS(A)

9919076

9919095

9919280

9919281

SERVICE MANUALS

Service Manuals

2004

2000--2005

120 XC SP / PRO X

9919307

Trail Sport

500 Indy, Supersport

9919300

Touring

340 Edge Touring, Trail Touring (Deluxe), Widetrak LX, 600 Edge Touring (50th), 800 Edge Touring

9919304

Frontier

Frontier Touring

9919305

Classic

340 Classic, 500 Classic, 550 Classic, 600 Classic, 800 Classic

9919301

Deep Snow

Trail RMK, 600/700/800 RMK, 600/800 Switchbackt, 900 RMK

9919302

Performance

500/600/700/800 XC SP, 900 Fusion

9919303

2005 Specification Handbook

9919311

2005 Snowmobile Wallcharts

9919309

Track Poster

9918459

Flat Rate Manual

9919308

Snowmobile Care and Adjusting for the Perfect Ride (DVD) (2004)

9918923

Snowmobile Care and Adjusting for the Perfect Ride (VHS) (2004)

9918908

2005 Snowmobile Quick Start Guide (DVD) (2005)

9919129

GENERAL INFORMATION

2.4

GENERAL SERVICE PRECAUTIONS

In order to perform service work efficiently and to prevent costly errors, the technician should read the text in this manual,

thoroughly familiarizing him/herself with procedures before beginning. Photographs and illustrations have been included with the

text as an aid. Notes, cautions and warnings have also been included for clarification of text and safety concerns. However, a

knowledge of mechanical theory, tool use and shop procedures is necessary to perform the service work safely and satisfactorily.

Use only genuine Polaris service parts.

Cleanliness of parts and tools as well as the work area is of primary importance. Dirt and foreign matter will act as an abrasive

and cause damage to precision parts. Clean the snowmobile before beginning service. Clean new parts before installing.

Watch for sharp edges which can cause personal injury, particularly in the area of the tunnel. Protect hands with gloves when

working with sharp components.

If difficulty is encountered in removing or installing a component, look to see if a cause for the difficulty can be found. If it is

necessary to tap the part into place, use a soft face hammer and tap lightly.

Some of the fasteners in the snowmobile were installed with locking agents. Use of impact drivers or wrenches will help avoid

damage to fasteners.

Always follow torque specifications as outlined throughout this manual. Incorrect torquing may lead to serious machine

damage or, as in the case of steering components, can result in injury or death for the rider(s).

If a torquing sequence is indicated for nuts, bolts or screws, start all fasteners in their holes and hand tighten. Then, following

the method and sequence indicated in this manual, tighten evenly to the specified torque value. When removing nuts, bolts or

screws from a part with several fasteners, loosen them all about 1/4 turn before removing them.

If the condition of any gasket or O-Ring is in question, replace it with a new one. Be sure the mating surfaces around the gasket

are clean and smooth in order to avoid leaks.

Some procedures will require removal of retaining rings or clips. Because removal weakens and deforms these parts, they

should always be replaced with new parts. When installing new retaining rings and clips use care not to expand or compress them

beyond what is required for installation.

Because removal damages seals, replace any oil or grease seals removed with new parts.

Polaris recommends the use of Polaris lubricants and greases, which have been specially formulated for the top performance

and best protection of our machines. In some applications, such as the engine, warranty coverage may become void if other brands

are substituted.

Grease should be cleaned from parts and fresh grease applied before reassembly of components. Deteriorating grease loses

lubricity and may contain abrasive foreign matter.

Whenever removing or reinstalling batteries, care should be taken to avoid the possibility of explosion resulting in serious

burns. Always disconnect the negative (black) cable first and reconnect it last. Battery electrolyte contains sulphuric acid and is

poisonous! Serious burns can result from contact with the skin, eyes or clothing. ANTIDOTE: External - Flush with water.

Internal - Drink large quantities or water or milk. Follow with milk of magnesia, beaten egg, or vegetable oil. Call physician

immediately. Eyes - Flush with water for 15 minutes and get prompt medical attention.

GENERAL INFORMATION

2.5

DECIMAL EQUIVALENTS

1/64

.0156

. . . . . . . . . . . . . . . . . .

1/32

.0312

1 mm = .0394″

. . . . . . . . . . . . .

. . . . . . . .

3/64

.0469

. . . . . . . . . . . . . . . . . .

1/16

.0625

. . . . . . . . . . . .

5/64

.0781

2 mm = .0787″

. . . . . . . . . . . . . . . . . .

. . . . . . . .

3/32

.0938

. . . . . . . . . . . . .

7/64

.1094

3 mm = .1181″

. . . . . . . . . . . . . . . .

. . . . . . . .

1/8.

.125

. . . .

9/64

.1406

. . . . . . . . . . . . . . . . . .

5/32

.1563

4 mm = .1575″

. . . . . . . . . . . .

. . . . . . . .

11/64

.1719

. . . . . . . . . . . . . . . . .

3/16

.1875

5 mm = .1969″

. . . . . . . . . . . .

. . . . . . . .

13/64

.2031

. . . . . . . . . . . . . . . . .

7/32

.2188

. . . . . . . . . . . .

15/64

.2344

6 mm = .2362″

. . . . . . . . . . . . . . . . .

. . . . . . . .

1/4

.250

. . . .

17/64

.2656

7 mm = .2756″

. . . . . . . . . . . . . . . . .

. . . . . . . .

9/32

.2813

. . . . . . . . . . . .

19/64

.2969

. . . . . . . . . . . . . . . . .

5/16

.3125

8 mm = .3150″

. . . . . . . . . . . .

. . . . . . . .

21/64

.3281

. . . . . . . . . . . . . . . . .

11/32

.3438

9 mm = .3543″

. . . . . . . . . . .

. . . . . . . .

23/64

.3594

. . . . . . . . . . . . . . . . .

3/8

.375

. . . .

25/64

.3906

10 mm = .3937″

. . . . . . . . . . . . . . . . .

. . .

13/32

.4063

. . . . . . . . . . .

27/64

.4219

11 mm = .4331″

. . . . . . . . . . . . . . . . .

. . . . . . . .

7/16

.4375

. . . . . . . . . . . .

29/64

.4531

. . . . . . . . . . . . . . . . .

15/32

.4688

12 mm = .4724″

. . . . . . . . . . .

. . . . . . . .

31/64

.4844

. . . . . . . . . . . . . . . . .

1/2

.5 00

13 mm = .5118″

. . . .

. . . . . . . . . . . . . . . . .

33/64

.5156

. . . . . . . . . . . . . . . . .

17/32

.5313

. . . . . . . . . . .

35/64

.5469

14 mm = .5512″

. . . . . . . . . . . . . . . . .

. . . . . . . .

9/16

.5625

. . . . . . . . . . . .

37/64

.5781

15 mm = .5906″

. . . . . . . . . . . . . . . . .

. . . . . . . .

19/32

.5938

. . . . . . . . . . .

39/64

.6094

. . . . . . . . . . . . . . . . .

5/8

.625

16 mm = .6299″

. . . .

. . . . . . . . . . . . . . . . .

41/64

.6406

. . . . . . . . . . . . . . . . .

21/32

.6563

17 mm = .6693″

. . . . . . . . . . .

. . . . . . . .

43/64

.6719

. . . . . . . . . . . . . . . .

11/16

.6875

. . . . . . . . . . .

45/64

.7031

18 mm = .7087″

. . . . . . . . . . . . . . . . .

. . . . . . . .

23/32

.7188

. . . . . . . . . . .

47/64

.7344

19 mm = .7480″

. . . . . . . . . . . . . . . . .

. . . . . . . .

3/4

.750

. . . .

49/64

.7656

. . . . . . . . . . . . . . . . .

25/32

.7813

20 mm = .7874″

. . . . . . . . . . .

. . . . . . . .

51/64

.7969

. . . . . . . . . . . . . . . . .

13/16

.8125

21 mm = .8268″

. . . . . . . . . . .

. . . . . . . .

53/64

.8281

. . . . . . . . . . . . . . . . .

27/32

.8438

. . . . . . . . . . .

55/64

.8594

22 mm = .8661″

. . . . . . . . . . . . . . . . .

. . . . . . . .

7/8

.875

. . . .

57/64

.8906

23 mm = .9055″

. . . . . . . . . . . . . . . . .

. . . . . . . .

29/32

.9063

. . . . . . . . . . .

59/64

.9219

. . . . . . . . . . . . . . . .

15/16

.9375

24 mm = .9449″

. . . . . . . . . . .

. . . . . . . .

61/64

.9531

. . . . . . . . . . . . . . . . .

31/32

.9688

25 mm = .9843″

. . . . . . . . . . .

. . . . . . . .

63/64

.9844

. . . . . . . . . . . . . . . . .

1.000

. . . . . .

GENERAL INFORMATION

2.6

STANDARD TORQUE SPECIFICATIONS

The following torque specifications are to be used as a general guideline when torque value is not specified. There are exceptions

in the steering, suspension, and engine areas. Always consult the torque chart and the specific manual section for torque values of

fasteners.

Bolt Size Threads/In

Grade 2

Grade 5

Grade 8

(MM/Thread)

Torque in. lbs. (Nm)

#10 -

27 (3.1)

43 (5)

60 (6.9)

. . . . . . . . . . .

. . . . . . . . . . . . .

. . . . . . . . . . . . . .

#10 -

31 (3.6)

49 (5.6)

68 (7.8)

. . . . . . . . . . .

. . . . . . . . . . . . .

. . . . . . . . . . . .

Torque ft. lbs. (Nm)*

1/4

5 (7)

8 (11)

12 (16)

. . . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . . . . .

1/4

6 (8)

10 (14)

14 (19)

. . . . . . . . . . .

. . . . . . . . . . . . . . .

. . . . . . . . . . . . .

5/16 -

11 (15)

17 (23)

25 (35)

. . . . . . . . . . .

. . . . . . . . . . . . .

5/16 -

12 (16)

19 (26)

29 (40)

. . . . . . . . . . .

. . . . . . . . . . . . .

3/8

20 (27)

30 (40)

45 (62)

. . . . . . . . . . .

. . . . . . . . . . . . .

3/8

23 (32)

35 (48)

50 (69)

. . . . . . . . . . .

. . . . . . . . . . . . .

7/16 -

30 (40)

50 (69)

70 (97)

. . . . . . . . . . .

. . . . . . . . . . . . .

7/16 -

35 (48)

55 (76)

80 (110)

. . . . . . . . . . .

. . . . . . . . . . . . .

1/2

50 (69)

75 (104)

110 (152)

. . . . . . . . . . .

. . . . . . . . . . . . .

. . . . . . . . . . . .

1/2

55 (76)

90 (124)

120 (166)

. . . . . . . . . . .

. . . . . . . . . . . . .

. . . . . . . . . . . .

*To convert ft. lbs. to Nm multiply foot pounds by 1.356.

*To convert Nm to ft. lbs. multiply Nm by .7376.

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