Snowmobile Polaris RMK Shift / RMK / Dragon RMK (2008 year). Manual - part 23

MAINTENANCE

Brakes

Brake Fluid

Replace brake fluid at least every two
years with Polaris DOT 4 high tem-
perature brake fluid. See page 112 for
the part numbers of Polaris products.

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

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 rap-

idly absorbs moisture from the air. The moisture causes the boiling tempera-

ture 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.

CAUTION

Brake fluid will damage decals, paint and some plastics. Always wipe up

spills immediately.

Sight Glass

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.

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 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" (.6-.8 cm) below the lip of the reservoir open-
ing. 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.

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

See page 93.

8. Reinstall the gasket and cover.

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.

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.

MAINTENANCE

Lights

Removing Halogen Bulbs

NOTE:

Do not touch a halogen bulb with bare fingers. Oil from skin leaves a

residue, causing a hot spot that will shorten the life of the lamp. If fin-

gers do touch the bulb, clean it with an alcohol-moistened towel.

1. Remove the plenum cov-

ering from the headlight
assembly.

2. Lift the rubber boot to

expose the bulb.

3. Push down on the spring

to release it from the
housing.

4. With the wire harness

attached to the bulb, with-
draw the bulb from the housing.

5. Grasp the bulb by its metal base and carefully separate the bulb

from the harness.

Installing Halogen Bulbs

1. Hold the bulb by its metal base and install it into the wire harness.

2. Insert the bulb into the housing.

3. Connect the spring to the housing.

4. Carefully flip the spring back into the housing, placing it around the

wire harness.

5. Reinstall the plenum covering on the headlight assembly.

6. Adjust headlight aim. See page 28.

Replacing Taillight Bulbs

1. Remove the screws securing

the taillight lens.

2. Remove the bulb and install a

new bulb.

3. Reinstall the lens.

Spring

Harness

Bulb

Screws

MAINTENANCE

Clutch System

Periodically inspect clutch sheaves for damage, wear or belt residue. To
maintain optimum performance, clean with non-oil based cleaners such
as isopropyl alcohol.

Clutch Alignment Offset

Clutch alignment offset is important for maintaining optimum perfor-
mance. Please see your Polaris dealer if you experience a decrease in
performance.

Clutch Center Distance

See your Owner's Manual Supplement for recommended center distance
for your machine. If adjustment is necessary, see your dealer.

WARNING

If you become aware of higher than normal clutch engagement or an unusual

vibration or shift pattern, see your dealer immediately. Do not operate the

snowmobile until repairs have been made.
All clutch maintenance and repairs must be performed by an authorized

Polaris dealer. Any unauthorized modifications to clutches, such as adding or

removing weights, will void the warranty.

CAUTION

The bushings in the weights and rollers of Polaris clutches are made of a

material that may be damaged if lubricated. Do not lubricate clutch bushings.

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