Snowmobile Polaris 650 Pro RMK 155 / 650 RMK Khaos 146 Slash / 850 Pro RMK 155. Owner’s Manual (2024)

TOWING

NOTICE

This snowmobile is not designed for towing disabled snowmobiles or other

objects. Do not tow with this snowmobile. Damage will occur.

If the snowmobile becomes inoperable and must be towed, and if it isn't possible
to use a rigid tow bar, attach the tow rope to the ski spindles (not to the ski loops)
to prevent damage to the steering components. Remove the drive belt before
towing, and have someone ride on the towed snowmobile to operate the brake
and steering when necessary.

NOTICE

Towing a disabled snowmobile with the drive belt in place can result in serious

damage to the engine and drive system. Always remove the drive belt from a

disabled snowmobile before towing.

132

OPERATION

EMISSIONS CONTROL SYSTEMS

EMISSION CONTROL INFORMATION

Any qualified repair shop or qualified person may maintain, replace, or repair the
emission control devices or systems on your snowmobile. An authorized
POLARIS dealer can perform any service that may be necessary for your
vehicle. POLARIS also recommends POLARIS parts for emissions related
service, however equivalent parts may be used for such service. It is a potential
violation of the Clean Air Act if a part supplied by an aftermarket parts
manufacturer reduces the effectiveness of the vehicle's emission controls.
Tampering with emission controls is prohibited by federal law.

Owners are responsible for performing the scheduled maintenance identified in
this owner’s manual.

EMISSION CONTROL LABEL

Your snowmobile is equipped at the time of sale with an emission control
information (ECI) label and a factory-installed emissions information hangtag.
These items are required by U.S. Environmental Protection Agency regulations.
The ECI label is permanently affixed to either the right side of the tunnel or the
engine recoil cover. The ECI label should not be removed, even after you
purchase the snowmobile. You may remove the factory-installed emissions
information hangtag, which is intended solely for your use in making a
purchasing decision.

EMISSION CONTROL MAINTENANCE
REQUIREMENTS

Your snowmobile is certified to operate on gasoline with a minimum octane level
of 87 (R+M)/2. If your snowmobile is equipped with a check engine light and it
comes on, you must take your snowmobile to an authorized POLARIS dealer for
diagnostic service. Specifications and adjustments for engine tune-ups are
located in the Service Manual, which is available to your qualified service
technician. Reverse (if equipped) must not be engaged during engine tune-ups.

OWNER'S RESPONSIBILITIES

Please read the Snowmobile Engine Emissions Limited Warranty, and read the
maintenance section of your owner's manual. You are responsible for ensuring
that the specified maintenance is performed. POLARIS recommends that you
contact an authorized POLARIS dealer, or other qualified person, to perform any
service that may be necessary.

NON-IONIZING RADIATION

This vehicle emits some electromagnetic energy. People with active or
non-active implantable medical devices (such as heart monitoring or controlling
devices) should review the limitations of their device and the applicable
electromagnetic standards and directives that apply to this vehicle.

133

EMISSIONS CONTROL SYSTEMS

MAINTENANCE

POLARIS RECOMMENDED MAINTENANCE
PROGRAM

NOTICE

Hot components can cause damage to plastic. Always make sure the exhaust

system and engine have cooled before tipping the snowmobile on its side for

service or inspection.

To ensure many trouble-free miles of snowmobiling enjoyment, follow
recommended regular maintenance and perform service checks as outlined in
this manual. Record maintenance and service in the Maintenance Log beginning
on page 235.

The recommended maintenance schedule on your snowmobile calls for service
and maintenance inspections at 150 miles (240 km), 500 miles (800 km) and
1000 miles (1600 km). These inspections should be performed by a qualified
service technician. For continued optimum performance and component life,
continue maintenance checks at 1000 mile (1600 km) intervals.

All necessary replacement parts and labor incurred, with the exception of
authorized warranty repairs, become the responsibility of the registered owner.

If, during the course of the warranty period, part failures occur as a result of
owner neglect in performing recommended regular maintenance, the cost of
repairs are the responsibility of the owner.

Personal safety is critical when attempting to service or make adjustments to
your snowmobile. If you're not familiar with safe service or adjustment
procedures and the use of tools, or if you don't feel comfortable performing
these tasks yourself, your authorized POLARIS dealer can provide any needed
service.

WARNING

Take precaution and wear appropriate PPE (gloves and safety glasses) when

servicing or inspecting areas under the hood, exhaust components, chassis

components, or rear suspension components for any items that could be

sharp.

135

MAINTENANCE

PRE-SEASON MAINTENANCE

The chart below outlines inspection procedures that should be performed before
the start of each riding season.

Air Box / Intake Ducts /
Intake Tubes

Inspect

Bogie / Wheel Condition /
Fastener Bolts

Inspect or Adjust

Brake Fluid Level / Leaks /
Fluid Condition

Inspect or Adjust

Brake Hose Condition /
Routing

Inspect or Adjust

Brake Lever

Inspect or Adjust

Brake Pads / Brake Disc

Inspect as needed

Controls

Inspect or Adjust the following:

• Auxiliary Shut-Off
• Throttle Release Switch
• Ignition Switch
• Headlights / Brake light / Taillights
• Hand / Thumbwarmers
• PERC Reverse System

Coolant Level

Inspect or Adjust

Cooling Hoses / Pipes

Inspect or Adjust

Drive / Driven Clutch
Condition

Inspect or Adjust; Clean if needed

Drive Belt Condition / Ride
Out

Inspect or Adjust

Engine Mounts

Inspect or Adjust

Exhaust System /
Retaining Springs / Heat
Shields

Inspect or Adjust

Front / Rear Suspension
Mounting Bolts

Inspect or Adjust

Front Limiter Strap

Inspect or Adjust

136

MAINTENANCE

Fuel / Vent Hoses

Inspect or Adjust

Hood / Seat / Chassis /
Engine Compartment

Clean if needed

Oil Hoses

Inspect or Adjust

QUICKDRIVE Belt

Inspect or Adjust

Rail Slide Condition

Inspect or Adjust

Rear Idler Wheel Bolts /
Adjuster Bolt Jam Nuts

Inspect or Adjust

Recoil Handle / Rope /
Function

Inspect or Adjust

Shocks / Springs

Inspect or Adjust

Ski Fasteners

Inspect or Adjust; Clean if needed

Ski Skags

Inspect or Adjust

Ski Toe Alignment /
Handlebar Centering

Inspect or Adjust

Spark Plugs

Inspect or Adjust

Steering Fasteners /
Linkage / Handlebars

Inspect or Adjust

Throttle Lever / Throttle
Cable

Inspect or Adjust

Track Alignment / Track
Tension

Inspect or Adjust

137

MAINTENANCE

POLARIS MAINTENANCE SCHEDULE

The intervals shown in this table are based on vehicles operated under normal
conditions.

Each interval is given in miles (kilometers). Service the components or systems
at that interval.

Continue to follow the maintenance schedule as miles/kilometers increase on
the vehicle. For example, after the 2000 miles (3200 km) service has been
completed, do the service every 2000 miles (3200 km).

Vehicles subjected to severe use must be serviced at 50% of the stated interval.
Examples of severe use include: constant high RPM use; prolonged low-speed
or heavy load operation; extended idle; short trips.

150 MILES (240 KM)

Brake Pads / Brake Disc

Inspect or Adjust

Rail Slide Condition

Inspect or Adjust

Ski Skags

Inspect or Adjust

Spark Plugs

Inspect or Adjust

Track Alignment / Track
Tension

Inspect or Adjust

500 MILES (800 KM)

Brake Pads / Brake Disc

Inspect or Adjust

Rail Slide Condition

Inspect or Adjust

Ski Skags

Inspect or Adjust

Spark Plugs

Inspect or Adjust

Track Alignment / Track
Tension

Inspect or Adjust

138

MAINTENANCE

1000 MILES (1600 KM)

Brake Pads / Brake Disc

Inspect or Adjust

Rail Slide Condition

Inspect or Adjust

Ski Skags

Inspect or Adjust

Spark Plugs

Inspect or Adjust

Track Alignment / Track
Tension

Inspect or Adjust

EVERY 2000 MILES (3200 KM)

Brake Fluid

Replace

Brake Pads / Brake Disc

Inspect or Adjust

Clutch Alignment / Offset

Inspect or Adjust

QUICKDRIVE Belt

Replace

Rail Slide Condition

Inspect or Adjust

Shocks (If serviceable)

Replace oil and recharge; Rebuild if needed.

Ski Skags

Inspect or Adjust

Spark Plugs

Replace

Track Alignment / Track
Tension

Inspect or Adjust

ADDITIONAL MAINTENANCE INTERVALS

Every 60 months / 5
years

50/50 Extended
Life Coolant

Replace Fluid

139

MAINTENANCE

HOOD/SIDE PANEL

The hood and side panels of the snowmobile protect the operator from moving
parts. Never operate a snowmobile with the hood or side panels open or
removed. Always ensure that the hood and side panels are securely in place
before starting the engine.

To open a side panel, rotate the two 1/4-turn fasteners at the upper edges of the
side panel. Release the side panel strap at the lower edge of the panel.

To remove an open side panel, pull the panel outward to release the tabs at the
lower edge of the panel.

Removing the hood is not recommended. Any service requiring the removal of
the hood should be performed by an authorized POLARIS dealer, or equivalent
person.

LUBRICATION

REAR SUSPENSION LUBRICATION

Lubricate the suspension pivot shafts with POLARIS All Season Grease at the
intervals outlined in the

Maintenance

chapter and before seasonal storage.

When operating in heavy, wet snow conditions, lubricate every 500 miles (800
km).

Lack of lubrication will adversely affect your ride and the life of the suspension.
For more information about suspension lubrication and adjustments, your
authorized POLARIS dealer can assist.

140

MAINTENANCE

SPARK PLUGS

SPARK PLUG RECOMMENDATIONS

NOTICE

Using non-recommended spark plugs can result in serious engine damage. A

spark plug with a heat range too high will always cause engine damage if the

engine is operated in conditions more severe than intended for that plug.

Always use the spark plugs recommended for your snowmobile.

A new engine can cause temporary spark plug fouling due to the lubricant added
during the assembly process. Avoid prolonged idle speeds, which cause plug
fouling and carbonization.

Refer to the Specifications chapter for the specific spark plug to be used in your
snowmobile.

Change the spark plugs at the intervals outlined in the Periodic Maintenance
section.

• Use recommended spark plugs with the proper gap. Refer to the

specifications section for the specific spark plug to be used in your
snowmobile.

• Use only resistor-type spark plugs.
• Torque spark plugs to specification.

TORQUE

Spark Plug

18-22 ft-lbs (24-30 N·m)

• Always carry spare spark plugs.

SPARK PLUG INSPECTION

Spark plug condition is indicative of engine operation. The spark plug firing end
condition should be read after the engine has been warmed up and the vehicle
has been driven at higher speeds. Immediately check the spark plug for correct
color.

WARNING

A hot exhaust system and engine can cause burns. Wear protective gloves

when removing a spark plug for inspection.

1. Remove the left side panel and hood.

2. Remove the spark plug cap.

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MAINTENANCE

3. Using the spark plug wrench provided in the tool kit, rotate the spark plug

counter-clockwise to remove it.

4. Reverse the procedure for spark plug installation. Torque to specification.

5. Reinstall the spark plug cap. Verify an “audible” click is heard when installing

the plug cap.

SPARK PLUG CONDITION

NORMAL PLUG

The normal insulator tip is gray, tan or light brown. There will be few combustion
deposits. The electrodes are not burned or eroded. This indicates the proper
type and heat range for the engine and the service.

TIP

The tip should not be white. A white insulator tip indicates overheating, caused

by use of an improper spark plug or incorrect carburetor/throttle body

adjustments.

WET FOULED PLUG

The wet fouled insulator tip is black. A damp oil film covers the firing end. There
may be a carbon layer over the entire nose. Generally, the electrodes are not
worn. General causes of fouling are excessive oil or use of non-recommended
injection oil.

INTAKE FILTERS

The intake filters

limit snow

ingestion into the intake system.
When operating in loose powder
snow, check the filters
periodically for damage and to
remove any accumulation of
snow.

FUEL PUMP

All fuel pump service must be performed by an authorized POLARIS dealer. Do
not attempt to service the fuel pump.

142

MAINTENANCE

FUEL FILTER / FUEL LINES

This snowmobile is not equipped with an in-line fuel filter. The fuel pump uses a
sock-type pickup filter located within the fuel tank. This filter should only require
maintenance if debris or foreign material enters the fuel tank. An authorized
POLARIS dealer can provide service.

Contaminated or poor quality fuel may shorten the life of fuel system
components and result in poor engine performance. Always store fuel in clean
fuel containers. If low fuel pressure or reduced engine performance occurs, the
filter may need replacement. An authorized POLARIS dealer can assist.

Inspect the fuel lines regularly for signs of deterioration or damage. Always
check fuel line condition after periods of storage. Normal deterioration from
weather and fuel compounds may occur. Replace worn or damaged fuel lines
promptly.

NOTICE

Kinking the fuel lines or using a pliers or similar tools to remove fuel lines may
cause damage to the lines. If a fuel line has been damaged or kinked, replace

it promptly.

COOLING SYSTEM

COOLANT

POLARIS recommends the use of POLARIS Antifreeze 50/50 Premix. This
antifreeze is already premixed and ready to use. Do not dilute with water. If the
vehicle will be stored or operated at extremely low temperatures, greater
protection may be required. An authorized POLARIS dealer can assist.

To ensure that the coolant maintains its ability to protect the engine, we
recommend that the system be completely flushed and drained every five (5)
years and fresh Antifreeze 50/50 Premix.

Any time the cooling system has been drained for maintenance or repair,
replace the coolant with fresh Antifreeze 50/50 Premix.

NOTICE

If coolant flow becomes restricted or plugged, coolant loss, air lock, or engine

damage may result. Most cooling systems are equipped with a filter that should

be periodically inspected or replaced.

143

MAINTENANCE

COOLANT LEVEL

The engine coolant level is controlled by the recovery system. The recovery
system components are:

• Coolant bottle/overflow tank
• Pressure cap
• Connecting hoses
• In-bottle Thermostat (650, 850, 9R and 850 Boost models only)

Always maintain the coolant level at or slightly above the FULL COLD mark on
the coolant bottle (when the engine is cold).

1. Stop the engine.

2. Open the right side panel.

3. View the coolant level in the coolant bottle. Add coolant as needed.

NOTICE

Operating the snowmobile with insufficient coolant will result in overheating

and serious engine damage. Always maintain the coolant level as

recommended.

FLUSHING THE COOLING SYSTEM

To ensure that the coolant maintains its ability to protect the engine, Polaris
recommend that the system be completely drained every five (5) years and fresh
Antifreeze 50/50 Premix added. This service must be performed when the
engine is cold. Your authorized POLARIS dealer can check the coolant when
performing the fall tune-up on your snowmobile.

BLEEDING THE COOLING SYSTEM

The cooling system is a self bleeding system.

CAUTION

Cooling system under pressure. Steam and hot liquids will cause burns to your

skin. Never bleed the cooling system or remove the pressure cap when the

engine is warm or hot. Wear eye protection when servicing the cooling system.

NOTICE

Pressure cap rated at 13 PSI (0.9 BAR). Use of a non-standard pressure cap

will not allow the recovery system to function properly.

144

MAINTENANCE

CAUTION

Perform this procedure in a well-ventilated area. Use the recommended 50/50

Extended-Life Antifreeze.

1. Remove right side panel.

2. Fill the coolant bottle to the COLD FILL mark.

3. Install the coolant bottle cap to the half lock position. Do not tighten to the

fully seated position.

4. Lock the parking brake.

5. Start the engine and allow it to run at a fast idle for several minutes, until the

tunnel coolers are warm to the touch.

CAUTION

Keep the coolant level in the coolant bottle at or near the COLD FILL mark

when engine is running. The engine may suck the coolant down quickly which

my require coolant to be added a few times to stabilize the coolant level.

6. When all tunnel cooler extrusions are warm to the touch, stop the engine.

7. Allow the engine and cooling system to cool.

8. Fill the coolant bottle to the COLD FILL mark. Reinstall the bottle cap

securely.

9. Reinstall the right side panel.

EXHAUST SYSTEM

Check the exhaust system for wear or damage at approximately 2000 miles
(3200 km). Always allow the engine and exhaust system to cool completely
before inspecting.

WARNING

Hot exhaust system parts can cause burns. Allow adequate time for the

exhaust system to cool. Never perform this procedure with the engine running.

1. Open the side panels and remove the hood. See page 140.

2. Inspect the muffler and pipes for cracks or damage.

3. Check for weak or missing retaining springs or damper/support grommets.

4. Check for loose clamps on the pipe covers.

145

MAINTENANCE

ELECTRONIC VARIABLE EXHAUST SYSTEM
(E-VES) MAINTENANCE

NOTICE

Improper cleaning or valve assembly installation may cause severe engine

damage! The ECU must be programmed by an authorized POLARIS dealer if

any component in the E-VES system is replaced or improperly serviced.

The engine in your Polaris snowmobile is equipped with E-VES. Periodic valve
inspection and cleaning is not required or recommended as the exhaust valves
do not rely on combustion pressure for operation. The E-VES system is
designed to work when oil and carbon deposits form on the valves.

At the time of assembly, the valve range of travel is programmed into the engine
management system. If blade travel is restricted for any reason, the engine
management system will alert the rider and turn on the check engine MIL.
E-VES service should only be performed by an authorized POLARIS dealer who
has the tools and diagnostic software to properly service and program the
system.

NOTICE

During engine break-in, E-VES diagnostic codes may appear during engine

operation as the valves wear into their cylinder slots. Contact your authorized

POLARIS dealer if the check engine MIL remains illuminated after the break-in

period.

QUICKDRIVE

QUICKDRIVE BELT CONDITION

Periodically check the condition of the QUICKDRIVE belt. Inspect the belt for
signs of excessive wear, frayed edges, missing cogs and cracks.

Replace the QUICKDRIVE belt every 2000 miles (3200 km) and whenever
inspection reveals excessive wear or damage. Special tools are required to
remove and install the QUICKDRIVE belt. An authorized POLARIS dealer or
other qualified technician can assist with this service, or refer to the instructions
provided with the purchase of a new belt.

Improper track tension can result in track ratcheting, which will affect
QUICKDRIVE belt durability. Always maintain proper track tension.

BRAKES

HYDRAULIC BRAKE INSPECTION

Inspect the brake lever reserve before each use of the snowmobile. See the
Brake Lever Travel section for procedure.

146

MAINTENANCE

Brake pads must be replaced when the brake pad material becomes thinner
than 1/16 inch (1.5 mm). A kit is available for replacing brake pads. Your
authorized POLARIS dealer can assist.

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 1/16 inch (1.5 mm).

BRAKE COMPONENTS

Brake Caliper

Brake Pad Material -

Replace when

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

Brake Disc

Brake Bleeder Valve

EXCESSIVE LEVER TRAVEL

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

TIP

The lightweight brake discs have vent holes that may cause a high-pitched

sound during operation.

BRAKE FLUID

Replace brake fluid at least every two years with POLARIS DOT 4 high
temperature brake fluid, or an equivalent product.

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.

147

MAINTENANCE

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.

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 possible. 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 4–5 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.

148

MAINTENANCE

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

147.

8. Reinstall the gasket and cover.

TORQUE

Master Reservoir Gasket

6-8 in-lbs (0.7-0.9 N·m)

LIGHTS

The headlight and taillight assemblies feature LED elements and are not
serviceable. If an LED fails to illuminate in either the headlight or taillight, the
entire assembly must be replaced. Please see your authorized POLARIS dealer.

FUSE REPLACEMENT

The brake system and ACC 2-amp fuses are located in the protective bag above
the clutch cover.

NOTICE

Always replace a blown fuse with a new fuse having the same amperage rating

of the blown fuse. Never replace a fuse with a fuse of a higher amperage

rating.

CONSTANT POWER FUSE

Models equipped with electric start have
a battery/electric start wire harness. The
2 amp constant power fuse

is located

in the electric start wiring harness.

This fuse protects KEY ON power at the
ignition switch. KEY ON power supplies
battery voltage to the PIDD and GPS
puck.

If the PIDD does not turn on when the key is in the ON position, check for a
blown fuse. If the fuse is blown, inspect the constant power circuit. Repair or
replace any damaged components before replacing the fuse.

149

MAINTENANCE

LOAD CENTER

The load center is located on a
bracket secured to the front
cross tube. To access the fuse
box, remove the side panels and
hood.

LOAD CENTER DETAILS

CIRCUIT

PIN

FUNCTION

Spare 10A Fuse

—

Spare 15A Fuse

—

Battery 6A Diode

Power In

Power Out

Gauge 6A Diode

Power In

Power Out

Battery Charge Relay

Coil High

150

MAINTENANCE

CIRCUIT

PIN

FUNCTION

Power In

Power Out

Coil Low

Fuel Pump 15A Fuse

Power In

Power Out

Test Circuit 6A Diode

Power In

Power Out

Gauge Power Relay

Coil High

Power In

Power Out

Coil Low

ECM Power 15A Fuse

Power In

Power Out

Headlight 10A Fuse

Power In

Power Out

EV Control 5A Fuse

Power In

Power Out

Brake Light 2A Fuse

Power In

Power Out

Rear Acc 10A Fuse

Power In

Power Out

Accessory 10A Fuse

Power In

Power Out

LHC Chassis 15A Fuse

Power In

Power Out

Spare 10A Fuse

Not Applicable

151

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.

WARNING

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

vibration or shift pattern, see your authorized POLARIS dealer or qualified

person immediately. Do not operate the snowmobile until repairs have been

made.

All clutch maintenance and repairs can be performed by an authorized
POLARIS dealer. Any unauthorized modifications to clutches, such as adding or
removing weights, will void the warranty.

NOTICE

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.

CLUTCH ALIGNMENT OFFSET

Clutch alignment offset is important for maintaining optimum performance. Your
authorized POLARIS dealer can assist with service and adjustments. A special
tool is required to check for proper alignment.

DRIVE BELT CONDITION

Periodically check the condition and tension of the drive belt. Inspect the belt for
signs of excessive wear (frayed edges, missing cogs, cracks) and excessive
looseness. Replace the belt if any of these conditions exist. See page 222.

Always carry a spare drive belt. Store the spare belt in the belt holder. When
placing the belt in the holder, orientate the belt to match the profile of the hood.

For improved drive-away during extremely cold temperatures, remove the belt
and warm it to room temperature. Reinstall it before starting the snowmobile.

BELT DEFLECTION INSPECTION

Measure belt deflection with both clutches at rest and in their full neutral
position.

152

MAINTENANCE

Place a straight edge on the belt and apply downward pressure while measuring
midway between both clutches.

MEASUREMENT

Belt Deflection:

1.25 in (3.2 cm)

DRIVE BELT DEFLECTION ADJUSTMENT (PATRIOT
650/850 MODELS)

NOTICE

Patriot Boost / 9R models feature self-adjusting belt deflection and do not

require belt deflection adjustments.

To adjust the drive belt, do the following:

153

MAINTENANCE

4. Using the L-wrench, open driven clutch sheaves 0.5 in.

5. Tighten deflection screw nut to specification.

TORQUE

Deflection Screw Nut

145 in-lbs (16.4 N·m)

6. Rotate belt clockwise while removing L-wrench.

DRIVE BELT REMOVAL

NOTICE

Do not attempt to remove the drive belt after operating in reverse. The

snowmobile must be stopped after forward motion to prevent damage to

components during belt removal. Rotate the driven clutch counter-clockwise

1/4 turn by hand to ensure forward engagement before attempting to remove

the belt.

1. Stop the engine after operating in a forward motion.

2. Turn the ignition key off. Wait for the engine to come to a complete stop.

3. Lock the parking brake.

4. Remove the left side panel.

155

MAINTENANCE

5. Rotate the driven clutch counter-clockwise 1/4 turn by hand to ensure

forward engagement.

6. Locate the L-wrench

in the left hand fender . Install the wrench into the

open threaded hole in the outer sheave of the clutch.

7. Turn the wrench clockwise until the sheaves open far enough to remove the

belt. If the wrench does not turn readily, rotate the driven clutch
counter-clockwise an additional 1/4 turn by hand and try again.

8. Remove the belt from the driven clutch.

DRIVE BELT INSTALLATION

1. With the L-wrench inserted into the threaded hole and the sheaves in the

open position, install the drive belt.

IMPORTANT

Install the belt so that the numbers can be read correctly on the left side of the

vehicle, or in the direction in which the belt was originally installed.

2. Rotate the belt clockwise to remove slack while removing the L-wrench.

3. Reinstall the side panel.

4. Break in the new belt. See page 119.

156

MAINTENANCE

TRACK MAINTENANCE

TRACK INSPECTION

WARNING

Broken track rods can cause a rotating track to come off the snowmobile,

which could cause serious injury or death. Never operate with a damaged

track. Never rotate a damaged track under power.

NOTICE

The figures below are for reference only. Your model may differ slightly.

1. Using a hoist, safely lift and

support the rear of the
snowmobile off the ground.

2. Rotate the track by hand to

check for damage.

3. Carefully examine the track

along the entire length of
each rod

. Bend the track

to check for breakage.

4. Replace the track if any rod damage is found.

157

MAINTENANCE

TRACK LUBRICATION

The slide rail needs snow for lubrication. Excessive wear indicates insufficient
lubrication. A new rail slide can cause faster heat build-up in limited lubrication,
resulting in excessive wear.

WARNING

Operating with insufficient lubrication between the rail slide and track guide

clips can cause track failure, loss of vehicle control and loss of braking ability,

which can result in serious injury or death. Avoid operating for extended

periods on ice and other surfaces that have little or no snow for lubrication.

If excessive rail slide wear occurs due to poor snow conditions, additional wheel
kits are available. Your authorized POLARIS dealer can provide more
information.

Track damage or failure caused by operation on ice or under other poor
lubrication conditions will void the track warranty.

TRACK TENSION

WARNING

Moving parts can cut and crush body parts. When performing the checks and

adjustments recommended on the following pages, stay clear of all moving

parts. Never perform track measurement or adjustments with the engine

running.

Track adjustment is critical for proper handling. Always maintain correct tension
and alignment. It is important to inspect adjust track tension after every ride for
the first 150 miles (240 kg) to ensure the proper tension during the break-in
period. Aggressive riders in certain snow conditions may need to adjust track
tension as early as 20 miles (32 kg). After the break-in period, track tension
should be inspected every 150 miles (240 kg).

IMPORTANT

Track adjustment is critical for proper handling. Always maintain correct

tension and alignment. Track tension must be kept at specification to avoid

inefficiency, premature wear, or drive train system failures.

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TRACK TENSION DATA CHART

Deep Lug Track

Type

Slack Measurement

Weight

Measurement/

Weight Location

2.0 Crossover

1-1.25 in

(2.5-3.2 cm)

10 lb

(4.54 kg)

16 in (40 cm)

ahead of rear

idler shaft

Series 6 (2.6 in)

Series 8 (2.75 in)

Series 9 (3.25 in)

TIP

Tension adjustments should be made only after the track is warmed up and

limber.

1. Turn the engine off.

2. Lift the rear of the snowmobile and safely support it off the ground.

3. Place the recommended weight or downward pressure on the track at the

specified distance (see chart) ahead of the center of the rear idler wheel.

4. Measure at the point where the weight is hanging.

5. Check for specified slack between the wear surface of the track clip and the

plastic slider. Refer to the Track Tension Data Chart above.

If the track needs adjustment:

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MAINTENANCE

6. Loosen the rear idler shaft bolt

7. Loosen the locknuts

8. Tighten or loosen the track adjusting screws

to provide equal adjustment

on both sides of the track.

9. Repeat the measurement on the other side of the track.

TIP

Check more frequently when the snowmobile is new.

10. Start the engine and slowly rotate the track at least five revolutions. Let the

track come to a stop (do not apply brakes).

11. Check track alignment and adjust as necessary.

12. Tighten the locknuts.

13. Tighten the idler shaft bolt.

TORQUE

Idler Shaft Bolt

55 ft-lbs (75 N·m)

TRACK ALIGNMENT

Periodically check that the track is centered and running evenly on the slide rails

. Misalignment will cause excessive wear to the track and slide rail.

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MAINTENANCE

1. Safely support the rear of the snowmobile with the track off the ground.

2. Start the engine and apply a small amount of throttle until the track turns

slowly at least five complete revolutions. Stop the engine and let the track
come to a stop (do not apply brakes).

3. Inspect track alignment by looking through the track window to make sure

the rails are evenly spaced on each side. If the track runs to the left, loosen
the idler shaft bolt, then loosen the left locknut and tighten the left adjusting
bolt. If the track runs to the right, loosen the idler shaft bolt, then loosen the
right locknut and tighten the right adjusting bolt.

4. After adjustments are complete, tighten the locknuts and torque the idler

shaft bolt to specification.

TORQUE

Idler Shaft Bolt

55 ft-lbs (75 N·m)

5. Repeat steps 2-3 to verify proper alignment.

STEERING SYSTEM

The steering systems on POLARIS snowmobiles can be adjusted with ski toe
alignment. Improper toe alignment can cause erratic steering. Your authorized
POLARIS dealer can assist with adjustments.

WARNING

Improper alignment or adjustment may cause loss of steering control, resulting

in serious injury or death. Do not attempt to change the ski alignment. Your

authorized POLARIS dealer can assist.

FRONT SUSPENSION INSPECTION

WARNING

Improper fastener torque or front suspension component damage may cause

loss of steering control, resulting in serious injury or death. Your authorized

POLARIS dealer can assist.

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Each week, or before a long ride, check the following items. If component
damage or loose fasteners are found, your authorized POLARIS dealer can
provide service.

Ski Bolt and Nuts

Tie Rod End Nuts

Upper/Lower Control Arm Nuts (8 per

side)

Sway Bar Fasteners

Shock Mounting Fasteners

Lower Control Arm Spindle Nuts

Upper Control Arm Spindle Nuts

Ski Loop Rear Fasteners

Ski Loop Front Fasteners

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SKI ALIGNMENT

WARNING

Improper ski alignment or adjustment may cause loss of steering control,

resulting in serious injury or death. Do not attempt to change the ski alignment

or camber adjustment. Your authorized POLARIS dealer can assist.

To align skis, do the following:

1. Place the handlebars in a straight-ahead position.

2. With only vehicle weight compressing the suspension, measure 10 in (25.4

cm)

forward from the center of the ski mounting bolt. From this point,

measure the distance between the skis

3. Measure 10 in (25.4 cm)

rearward from the center of the ski mounting bolt.

From this point, measure the distance between the skis

4. Measurement

should be 1/8 in (3 mm) greater than measurement

SKI SKAGS

WARNING

Worn skis and/or skags will adversely affect handling. Loss of vehicle control

may result, causing serious injury or death. See your authorized POLARIS

dealer's studding chart for recommended skags.

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Snowmobile Polaris 650 Pro RMK 155 / 650 RMK Khaos 146 Slash / 850 Pro RMK 155. Owner’s Manual (2024) - page 5