Polaris 600 RMK 2010-2012 Workshop Repair Service Manual
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Basic Information Identification Make: Polaris Model: RMK 600 Model Years Covered: 2010, 2011, 2012 Introduction Market Position Segment: High-performance mountain snowmobile. Target User: Snowmobile enthusiasts, recreational riders, and professional technicians. Competitive Analysis Competitors Era: Competed with similar displacement models from Ski-Doo (e.g., MXZ, Summit), Arctic Cat (e.g., M Series), and Yamaha (e.g., Nytro). Key Features Rmk Platform: RMK (Ridge, Mountain, King) platform known for its deep snow capability and agile handling. Engine Heritage: Leverages Polaris's reliable Liberty engine platform. Suspension Design: Features a robust and proven suspension system optimized for off-trail riding. Manual Details Coverage Areas Manual Type: Workshop Service Repair Manual Language: English Format: PDF Download Manual Coverage Systems Covered Engine: Complete engine disassembly, assembly, diagnostics, and repair of the 600cc Liberty twin-cylinder liquid-cooled engine. Fuel System: Fuel pump, fuel injectors, throttle body, fuel lines, and fuel filter service and troubleshooting. Ignition System: Ignition coil, spark plugs, CDI unit, stator, and wiring diagnostics. Cooling System: Radiator, coolant hoses, water pump, thermostat, and fan operation and maintenance. Exhaust System: Exhaust manifold, muffler, and catalytic converter inspection and replacement. Drivetrain: Primary clutch, secondary clutch, drive belt inspection and replacement, chaincase inspection, and lubrication. Suspension: Front and rear suspension components, shocks, springs, A-arms, and linkage inspection, adjustment, and replacement. Steering: Handlebar assembly, steering post, tie rods, and ski spindles inspection and service. Brakes: Brake caliper, master cylinder, brake lines, brake fluid, and brake pad service and bleeding procedures. Electrical System: Wiring diagrams, battery maintenance, starter system, lighting system, and accessory circuits. Procedures Included Maintenance: Scheduled maintenance tasks including oil changes, filter replacements, spark plug service, and lubrication points. Troubleshooting: Diagnostic flowcharts and symptom-based troubleshooting guides for common mechanical and electrical issues. Repair: Detailed step-by-step instructions for component removal, repair, and reinstallation. Rebuilds: Comprehensive engine and transmission (clutch system) rebuild procedures with torque specifications. Adjustments: Carburetor/throttle body synchronization, clutch alignment, and suspension settings. Inspection: Pre-ride inspections, wear assessment for critical components, and general condition checks. Technical Depth Level Of Detail: Designed for mechanical technicians, offering in-depth diagnostic procedures, component-level repair, and detailed specifications. Diagnostic Capabilities: Covers common fault codes, sensor diagnostics, and electrical system testing procedures. Component Specs: Provides detailed specifications for critical components including tolerances, wear limits, and torque values. Manual Specifications File Format File Type: PDF Searchability: Likely text-searchable PDF for efficient information retrieval. Printability: Printable, allowing for physical copies for workshop use. Resolution: High-resolution images and diagrams for clarity. Binding Type Digital Format: No physical binding (digital download). Paper Type Digital Format: N/A (digital). Engine Specifications Primary Engine Engine Type: Polaris 600 Liberty Twin Cylinders: 2 Displacement: 599cc Cooling System: Liquid-cooled Bore X Stroke: 73.0 mm x 72.0 mm (Typical for this generation) Intake: Electronic Fuel Injection (EFI) Performance Horsepower Estimate: ~125 hp (Approximate, varies by year and specific configuration) Torque Estimate: Data not explicitly provided but expected to be strong for its class. Fuel System Fuel Type: Unleaded gasoline Fuel Delivery: Electronic Fuel Injection (EFI) Throttle Body Size: Typically 48mm for this era EFI engines. Transmission Standard Type: CVT (Continuously Variable Transmission) with Polaris Variable Transmission (PVT) system Clutches: Team Tied Primary Clutch and Polaris P-85 Secondary Clutch (common configuration) Drive System: Snowmobile drive belt system Features Gear Selection: Forward, Neutral, Reverse (often electrically actuated or manual lever) Clutch Calibration: Details on clutch weights, spring rates, and helix angles for optimal performance tuning. Dimensions Exterior Chassis Type: Pro-Ride Chassis (for 2010-2012 RMK models, known for lightweight and rigidity) Track Length: Commonly 155 inches for mountain RMK models of this era. Track Width: Typically 15 inches. Lug Height: Commonly 2.25 inches or 2.375 inches for deep snow. Weights Dry Weight Estimate: ~450-470 lbs (approximate, depending on specific trim and features) Safety Features Ratings Crash Test Data: Snowmobiles are not subject to standardized crash ratings like automobiles. Safety is primarily dependent on rider skill and adhering to safe operating practices. Active Features Braking System: Hydraulic disc brake with braided stainless steel lines for improved feel and performance. Throttle Safety: Thumb throttle with adjustable tension and safety detent. Passive Features Ergonomics: Pro-Ride chassis designed for rider comfort and control during aggressive riding. Lighting: Halogen headlight and taillight for visibility. Technology Features Infotainment Display Panel: Digital gauge cluster displaying speed, RPM, odometer, trip meter, fuel level, and warning lights. Lighting Controls: Handlebar-mounted controls for headlights and auxiliary lighting (if equipped). Driver Assistance Braking Assistance: No advanced electronic braking assistance systems (e.g., ABS) typically found on this model year. Connectivity Accessory Power: Often includes a 12V accessory outlet for charging devices or powering accessories. Maintenance Service Intervals Oil Change: Typically every 1,000 miles or annually, check specific manual for exact interval. Belt Inspection: Regular inspection for wear and damage, replacement recommended every 2,000-3,000 miles or as needed. Spark Plugs: Inspect at 1,000 miles, replace as needed or per manual recommendation (e.g., every 2,000 miles)....
Scheduled maintenance tasks including oil changes, filter replacements, spark plug service, and lubrication points.
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting guides for common mechanical and electrical issues.
Repair:
Detailed step-by-step instructions for component removal, repair, and reinstallation.
Rebuilds:
Comprehensive engine and transmission (clutch system) rebuild procedures with torque specifications.
Adjustments:
Carburetor/throttle body synchronization, clutch alignment, and suspension settings.
Inspection:
Pre-ride inspections, wear assessment for critical components, and general condition checks.
Technical Depth
Level Of Detail:
Designed for mechanical technicians, offering in-depth diagnostic procedures, component-level repair, and detailed specifications.
Diagnostic Capabilities:
Covers common fault codes, sensor diagnostics, and electrical system testing procedures.
Component Specs:
Provides detailed specifications for critical components including tolerances, wear limits, and torque values.
Manual Specifications
File Format
File Type:
PDF
Searchability:
Likely text-searchable PDF for efficient information retrieval.
Printability:
Printable, allowing for physical copies for workshop use.
Resolution:
High-resolution images and diagrams for clarity.
Binding Type
Digital Format:
No physical binding (digital download).
Paper Type
Digital Format:
N/A (digital).
Engine Specifications
Primary Engine
Engine Type:
Polaris 600 Liberty Twin
Cylinders:
2
Displacement:
599cc
Cooling System:
Liquid-cooled
Bore X Stroke:
73.0 mm x 72.0 mm (Typical for this generation)
Intake:
Electronic Fuel Injection (EFI)
Performance
Horsepower Estimate:
~125 hp (Approximate, varies by year and specific configuration)
Torque Estimate:
Data not explicitly provided but expected to be strong for its class.
Fuel System
Fuel Type:
Unleaded gasoline
Fuel Delivery:
Electronic Fuel Injection (EFI)
Throttle Body Size:
Typically 48mm for this era EFI engines.
Transmission
Standard
Type:
CVT (Continuously Variable Transmission) with Polaris Variable Transmission (PVT) system
Clutches:
Team Tied Primary Clutch and Polaris P-85 Secondary Clutch (common configuration)
Drive System:
Snowmobile drive belt system
Features
Gear Selection:
Forward, Neutral, Reverse (often electrically actuated or manual lever)
Clutch Calibration:
Details on clutch weights, spring rates, and helix angles for optimal performance tuning.
Dimensions
Exterior
Chassis Type:
Pro-Ride Chassis (for 2010-2012 RMK models, known for lightweight and rigidity)
Track Length:
Commonly 155 inches for mountain RMK models of this era.
Track Width:
Typically 15 inches.
Lug Height:
Commonly 2.25 inches or 2.375 inches for deep snow.
Weights
Dry Weight Estimate:
~450-470 lbs (approximate, depending on specific trim and features)
Safety Features
Ratings
Crash Test Data:
Snowmobiles are not subject to standardized crash ratings like automobiles. Safety is primarily dependent on rider skill and adhering to safe operating practices.
Active Features
Braking System:
Hydraulic disc brake with braided stainless steel lines for improved feel and performance.
Throttle Safety:
Thumb throttle with adjustable tension and safety detent.
Passive Features
Ergonomics:
Pro-Ride chassis designed for rider comfort and control during aggressive riding.
Lighting:
Halogen headlight and taillight for visibility.
Technology Features
Infotainment
Display Panel:
Digital gauge cluster displaying speed, RPM, odometer, trip meter, fuel level, and warning lights.
Lighting Controls:
Handlebar-mounted controls for headlights and auxiliary lighting (if equipped).
Driver Assistance
Braking Assistance:
No advanced electronic braking assistance systems (e.g., ABS) typically found on this model year.
Connectivity
Accessory Power:
Often includes a 12V accessory outlet for charging devices or powering accessories.
Maintenance
Service Intervals
Oil Change:
Typically every 1,000 miles or annually, check specific manual for exact interval.
Belt Inspection:
Regular inspection for wear and damage, replacement recommended every 2,000-3,000 miles or as needed.
Spark Plugs:
Inspect at 1,000 miles, replace as needed or per manual recommendation (e.g., every 2,000 miles).
Fluid Specifications
Engine Oil:
Polaris Premium 2-Stroke Synthetic Oil or equivalent API TC-W3 certified oil. Capacity: Approx. 2.4 quarts (2.3 liters).
Coolant:
Ethylene glycol-based antifreeze (e.g., Polaris Coolant) with a 50/50 mix of coolant and distilled water. Capacity: Varies, check manual.
Chaincase Oil:
Polaris Synthetic Chaincase Lubricant or equivalent. Capacity: Approx. 10 oz (0.3 liters).
Brake Fluid:
DOT 4 brake fluid.
Known Issues
Clutch Wear:
Normal wear on primary and secondary clutch components, requires regular inspection and potential replacement of buttons, rollers, or bushings.
Suspension Bushings:
Wear in suspension pivot points and bushings can lead to play and affect handling; regular lubrication and inspection are key.
Efi System:
While generally reliable, occasional issues with fuel pump or injector cleanliness can occur; proper fuel usage and maintenance are important.
Track Tension:
Improper track tension can lead to premature wear on track and suspension components.
Vehicle History
Brand Heritage
Manufacturer:
Polaris Industries Inc., a long-standing American manufacturer of powersports vehicles.
Model Evolution
Rmk Lineage:
The RMK line has a storied history in deep snow and mountain riding, known for innovation in track technology and chassis design.
Pro-Ride Chassis:
Introduction of the Pro-Ride chassis represented a significant step forward in weight reduction and chassis stiffness for improved handling.
Production
Manufacturing Location:
Primarily manufactured in Roseau, Minnesota, USA.
Awards & Recognition
Recognitions
Industry Reputation:
Polaris RMK models have consistently received high marks from snowmobile publications for their deep snow performance and handling capabilities.
Pro-Ride Impact:
The Pro-Ride chassis itself was a significant technological advancement praised for its rider-forward design and improved agility.
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