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Polaris 850 PRO-RMK 155 2020 User Manual

Polaris 850 PRO-RMK 155 2020
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FOREWORD
The information printed within this publication includes the latest product information at time of print. The most recent
version of this Service Manual is available in electronic format at www.polarisdealers.com.
This Service Manual is designed primarily for use by certified Polaris Master Service Dealer
®
technicians in a properly
equipped shop and should be kept available for reference. All references to left and right side of the vehicle are from
the operator's perspective when seated in a normal riding position.
Some procedures outlined in this manual require a sound knowledge of mechanical theory, tool use, and shop
procedures in order to perform the work safely and correctly. Technicians should read the text and be familiar with the
service procedures before starting any repair. Certain procedures require the use of special tools. Use only the proper
tools as specified. If you have any doubt as to your ability to perform any of the procedures outlined in this Service
Manual, contact an authorized dealer for service.
We value your input and appreciate any assistance you can provide in helping make these publications more useful.
Please provide any feedback you may have regarding this manual. Authorized dealers can submit feedback using 'Ask
Polaris'. Click on 'Ask Polaris', and then click on 'Service Manual / Service Literature Question'.
Consumers, please provide your feedback in writing to: Polaris Industries Inc. ATTN: Service Publications Department,
2100 Hwy 55, Medina, MN 55340.
Publication Printed October 2020 (PN 9850060 R02)
© Copyright 2020 Polaris Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant
improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this
publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting
or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. Printed in U.S.A.
2020-2021 850 AXYS™ Long Track
Snowmobile

Table of Contents

Questions and Answers:

Polaris 850 PRO-RMK 155 2020 Specifications

General IconGeneral
Engine850 Patriot
Engine Type2-stroke
Displacement840 cc
Cylinders2
CoolingLiquid
Horsepower165 hp
Fuel SystemElectronic Fuel Injection
Fuel Capacity11.5 US gal (43.5 L)
Track Length155 in (393.7 cm)
Track Width15 in (38.1 cm)
BrakeHydraulic disc
Width48 inches

Summary

Chapter 1: General Information

Vehicle Identification

Details model number designation and VIN designation for vehicles from 2017 onwards.

Reference Information

Lists information regarding replacement keys and publication part numbers for 2020 and 2021 models.

Special Tools

Lists specialized tools required for servicing Polaris products and how to order them.

Model Specifications (Model Year 2020)

Provides detailed specifications for various 2020 Polaris Snowmobile models.

Service Precautions

Outlines essential safety and procedural precautions for performing service work efficiently.

General Diagnostics

Details diagnostic trouble codes (DTCs) for engine electrical systems, including SPN, FMI, P-CODE, fault, and condition.

Digital Wrench Diagnostic Software Overview

Provides an overview of the Digital Wrench software features and diagnostic procedures.

Chapter 2: Maintenance

Maintenance Program Overview

Outlines recommended maintenance and service inspections based on vehicle mileage.

Pre-Ride Inspection

Lists items to inspect before riding the snowmobile, covering drive clutch, engine, and brake systems.

Pre-Season Maintenance

Details pre-season maintenance checks for various systems including drive/driven clutch, engine, and brake systems.

Periodic Maintenance Chart

Provides a chart outlining required maintenance and inspection based on vehicle miles.

Lubricants / Service Products

Lists recommended lubricants and service products with part numbers and sizes.

Cooling System Maintenance

Covers cooling system overview, coolant level check, and coolant bottle assembly.

Drive Belt / Clutch Maintenance

Explains procedures for drive belt removal, installation, and inspection.

Clutch Alignment / Offset

Details how to measure and adjust clutch alignment and offset using various alignment tools.

Chapter 3: Engine / Cooling / Exhaust

Torque Specifications - Engine

Lists engine component torque specifications for various fasteners.

Service Specifications

Provides critical engine service specifications such as cylinder head warp, taper, and piston ring gap.

Special Tools

Lists and illustrates specialized tools required for engine service.

Electronic Oil Pump

Covers electronic oil pump mounting and flow offset identification.

Crankcase Disassembly

Provides step-by-step instructions for disassembling the crankcase.

Crankshaft Removal

Explains the procedure for removing the crankshaft from the engine.

Water Pump Service

Covers water pump removal and installation procedures.

Engine Assembly - Top End

Provides instructions for engine top-end assembly, including piston installation.

Recoil Assembly View

Illustrates the components of the recoil assembly with part number references.

EV Actuator Learn Procedure

Outlines the procedure to learn the E-VES actuator stop positions using Digital Wrench.

Chapter 4: Engine Electrical

General Information

Provides general information about the diagnostic power connector and its functions.

Engine Protection Features

Explains engine temperature and detonation protection modes and troubleshooting.

Cleanfire Fuel Injection (CFI) System Overview

Provides an overview of the components and functions of the Cleanfire Fuel Injection system.

Exhaust Gas Temperature (EGT) Sensor

Details the EGT sensor location, testing, and torque specifications.

Crankshaft Position Sensors (CPS)

Explains the function and testing of crankshaft position sensors and their specifications.

Ignition Coil Packs

Covers ignition coil pack location, specifications, and testing.

Electronic Control Unit (ECU)

Provides ECU connector pinouts for both 34-pin connectors.

ECU Label Information

Explains how to interpret the ECU label information for engine program, fuel injector color, and oil pump offset.

Throttle Position Sensor (TPS)

Covers TPS overview, testing procedures, and wire routing.

Polaris Electronic Reverse Control (PERC)

Provides an overview of PERC operation, forward operation, and troubleshooting notes.

Chapter 5: Fuel System

Service Warnings

Provides critical safety warnings for servicing the fuel system.

Fuel Pump Prime Procedure

Details the procedure to purge air from the fuel system and prime the fuel pump.

Fuel Type Selection

Explains how to change the fuel type designation in the gauge display.

Fuel Injectors / Fuel Rail / Throttle Body

Provides assembly views for the fuel rail and throttle body components.

Fuel Rail / Fuel Injector Service

Covers the service procedures for fuel injectors and fuel rail.

Fuel Tank / Fuel Pump Service

Covers fuel tank and fuel pump service procedures.

Fuel Pump Harness Routing

Shows how to route the fuel pump wire harness.

Fuel Line Routing

Illustrates the routing for the fuel supply and return lines.

Chapter 6: Final Drive / Brake Systems

General Information

Provides general information about drive gears and chains.

Chaincase Service

Covers chaincase assembly view, drive chain tension adjustment, and oil level checks.

QuickDrive Low Inertia Drive System

Provides assembly views for the QuickDrive low inertia drive system.

Driveshaft Service

Covers driveshaft assembly views, removal, and installation.

Jackshaft Service

Details jackshaft assembly views, removal, and installation procedures.

Brake System

Provides general notes, inspection procedures, and bleeding instructions for the brake system.

Brake System Bleeding

Covers the procedure for bleeding the brake system to remove air.

Apollo Brake Pad Inspection / Replacement

Details how to inspect and replace Apollo brake pads.

Brake Caliper Piston / Seal Replacement

Provides instructions for replacing brake caliper pistons and seals.

Brake Disc Inspection / Replacement

Details how to inspect and replace the brake disc.

Brake Line Routing (Quick Drive)

Illustrates the routing of brake lines for Quick Drive systems.

Chapter 7: PVT System

General Information

Provides general information about the PVT system, including special tools and drive spring terminology.

Drive Belt Specifications

Lists drive belt specifications including part number, width, and circumference.

Drive Belt Removal - AXYS

Details the procedure for removing the drive belt from AXYS models.

Drive Clutch Identification

Explains how to identify the drive clutch by its part number and markings.

Drive Clutch Assembly View

Illustrates the components of the drive clutch assembly.

Drive Clutch Removal

Outlines the steps for removing the drive clutch.

Drive Clutch Disassembly

Details the procedure for disassembling the drive clutch.

Roller Removal

Covers the removal of rollers, buttons, and pins from the spider.

Roller Installation

Provides instructions for installing rollers, buttons, and pins into the spider.

Bushing / Insert Replacement

Covers the replacement of drive clutch moveable sheave and cover bushings.

Clutch Alignment / Offset

Details how to measure and adjust clutch alignment and offset using various alignment tools.

Belt-To-Sheave Clearance Adjustment

Explains how to measure and adjust belt-to-sheave clearance.

Chapter 8: Steering / Suspensions

General Information

Provides general information and inspection guidelines for steering and suspension components.

Steering / Suspension General Inspections

Outlines components to check for wear or damage in steering and front suspension systems.

Rod End Alignment

Details how to ensure rod ends in suspension assemblies are parallel after installation.

Toe Specifications

Explains how toe alignment is measured at ride height and provides specifications.

Front Suspension (IFS) Factory Spring Settings

Lists factory spring settings for the front IFS suspension.

Front Suspension (IFS) Factory Clicker Settings

Details factory clicker settings for the front IFS suspension.

Rear Suspension

Covers rear track shock factory spring and clicker settings.

Shocks

Lists shock rebuilding tools and specifications for 2020 and 2021 models.

Walker Evans Piggyback Shock Disassembly

Details the procedure for disassembling the Walker Evans Piggyback shock.

Shock Assembly

Covers shock assembly procedures, including IFP installation and bleeding.

Chapter 9: Chassis

General Information

Provides general cautions and notes for working with chassis components and bonded parts.

Chassis Assembly Views

Illustrates various chassis assembly views, including right bulkhead, left bulkhead, clutch guard, and over structure.

Bonded Component Service

Provides information on Lord 406 Acrylic Adhesive handling and first aid measures for bonded components.

Bulkhead Floor Plate Removal

Outlines the procedure for removing the bulkhead floor plate.

Front Tunnel Bulkhead Cooler Installation

Covers the installation of the front tunnel bulkhead cooler.

Bulkhead Clip Installation, Left

Covers the installation of the left bulkhead clip, including adhesive application and fastener torquing.

Bulkhead Clip Installation, Right

Details the installation of the right bulkhead clip, including adhesive application and fastener torquing.

Chapter 10: Battery / Electrical

General Information

Provides general electrical system cautions, spark plug specs, and charging system information.

Electrical System General Cautions

Lists essential safety precautions for working with electrical systems.

Diagnostic Power Connector

Explains the function of each connector on the Next-Gen Service Power Harness.

Electrical Harness

Illustrates chassis harness connectors with pinout and function details.

Battery Maintenance

Covers battery maintenance for Dry Shipped AGM and Lead Acid Low Maintenance types.

Battery Identification

Important information on identifying battery types for proper service.

Dry Shipped AGM Battery Charging and Testing

Guides on charging and testing Dry Shipped AGM batteries.

AGM Low Maintenance Battery Testing

Details testing procedures for AGM Low Maintenance batteries.

Digital Instrument Cluster / Security

Covers general display information and cold engine protection modes.

Standard Instrument Cluster Overview

Provides an overview of the standard instrument cluster features and functionality.

Security System - Enable / Disable / Passcode Reset

Outlines procedures for enabling, disabling, and resetting the security system.

Security System - AXYS User Notes

Provides user notes and important information regarding the security system on AXYS models.

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