Polaris 700 Dragon RMK 163 2008 Repair Service Manual

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Typ: Snowmobile

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Art.-Nr: 89474

Stichworte: 2008 700 Dragon RMK 163 ATV Misc Polaris Powersports Snowmobile

Produktvarianten

Beschreibung

The 2008 Polaris Dragon RMK 163 is a high-performance snowmobile engineered for challenging mountain and backcountry terrain. Built on the robust RMK platform, this model features a lightweight chassis, a powerful liquid-cooled 2-stroke 698cc Liberty engine, and a 163-inch track designed for superior flotation and climbing ability. Its rider-forward ergonomics and specialized components, including the P-85 primary and P-90 secondary clutches, contribute to its reputation as a capable and reliable machine for demanding off-trail adventures. This comprehensive workshop repair service manual provides detailed information essential for the maintenance, troubleshooting, and repair of your 2008 Polaris Dragon RMK 163. It covers all major systems, including engine mechanicals, fuel, ignition, cooling, exhaust, drive, and electrical systems, as well as front and rear suspension, and brakes. The manual includes step-by-step procedures for routine maintenance, engine rebuilds, clutch calibration, and electrical diagnostics, offering in-depth technical guidance for owners and technicians alike.

🏷️ Basic Information

Identification

Make:

Polaris

Model:

Dragon RMK 163

Year:

Vehicle Type:

Snowmobile

Codes

Engine Code:

Likely a designation specific to Polaris for the 700cc engine, e.g., Liberty 700

Chassis Code:

RMK platform

👋 Introduction

Market Position

Segment:

High-performance mountain/backcountry snowmobile.

Key Selling Points:

Lightweight chassis, powerful 2-stroke engine, long track for flotation and climbing ability, rider-forward ergonomics.

Competitive Analysis

Competitors 2008:

Ski-Doo Summit, Arctic Cat M-Series, Yamaha Nytro.

Key Features

Distinctive Features:

Liberty 700 engine, RMK chassis, 163-inch track length for exceptional deep snow performance.

📋 Manual Details

Coverage Areas

Primary Coverage:

Service, Maintenance, Troubleshooting, Repair

Page Count

Estimated Page Count:

Likely 400-600 pages (typical for comprehensive service manuals)

Manual Type

Manual Type:

Workshop Repair Service Manual

Language

Language:

English

Format

Format:

PDF Download

📖 Manual Coverage

Systems Covered

Engine Mechanical:

Engine disassembly, assembly, inspection, repair of all internal components (pistons, rings, crankshaft, connecting rods, valves, camshafts), cylinder head, cylinder block.

Fuel System:

Carburetor (likely Mikuni VM series) tuning, cleaning, rebuilding; fuel pump, fuel lines, fuel filter replacement.

Ignition System:

CDI unit, ignition coils, spark plugs, wiring, troubleshooting ignition timing issues.

Cooling System:

Radiator, cooling fan, coolant hoses, thermostat, coolant specifications, bleeding procedures.

Exhaust System:

Exhaust pipes, muffler, mounting hardware, gasket replacement.

Drive System:

Drive clutch (primary), driven clutch (secondary), drive belt inspection and replacement, gearcase lubrication, chaincase inspection and service, driveshaft, sprockets.

Suspension Front:

IFS (Independent Front Suspension) components, A-arms, ball joints, tie rods, shock absorbers, springs, steering components, alignment specifications.

Suspension Rear:

RMK rear suspension system, rails, shocks (front and rear), springs, bogey wheels, track tension adjustment, lubrication, geometry.

Brakes:

Hydraulic brake system, brake caliper overhaul, brake pads replacement, brake fluid specifications and bleeding, brake disc inspection.

Electrical System:

Wiring diagrams, battery maintenance, stator, rectifier/regulator, lighting (headlights, taillights, brake lights), gauge cluster, starter system, kill switch functionality.

Bodywork Chassis:

Tunnel repair, plastic body panel removal and installation, seat, handlebars, controls, skid plate, bumper.

Procedures Included

Routine Maintenance:

Pre-ride inspection checklists, oil changes, filter replacements, lubrication points, track inspection, clutch maintenance.

Troubleshooting Guides:

Diagnostic procedures for common problems (e.g., starting issues, poor performance, overheating), symptom-based troubleshooting charts.

Engine Rebuild:

Complete step-by-step instructions for engine disassembly, cleaning, inspection, measurement, and reassembly.

Clutch Calibration:

Adjusting primary and driven clutches for optimal performance, belt alignment.

Suspension Tuning:

Adjusting suspension settings for different riding conditions, shock servicing.

Electrical Diagnostics:

Using wiring diagrams to diagnose electrical faults, testing components.

Technical Depth

Depth Level:

Comprehensive: Covers everything from basic fluid checks and belt replacement to complete engine teardown and rebuild, suspension component replacement, and electrical system diagnostics.

📊 Manual Specifications

File Format

File Type:

Searchability:

Likely text-searchable if digitally generated or well-scanned.

Print Quality

Print Readability:

High-resolution images and clear text for easy reading and printing.

Binding Type

Binding:

N/A (Digital Download)

Paper Type

Paper Quality:

N/A (Digital Download)

⚙️ Engine Specifications

Primary Engine

Engine Type:

Liquid-cooled, 2-stroke, twin-cylinder

Displacement:

698 cc

Bore X Stroke:

Typically around 80 mm x 68 mm (exact specs in manual)

Power Output:

Approximately 115-120 HP (exact dyno figures vary)

Torque Output:

Likely in the 70-75 lb-ft range (exact figures in manual)

Fuel System

Fuel Delivery:

Carbureted (likely dual Mikuni VM series, e.g., VM40)

Fuel Type:

87-91 octane unleaded gasoline (check manual for exact octane recommendation)

Lubrication

Oil System:

Autolube oil injection system.

Recommended Oil:

Polaris 2-stroke synthetic oil or equivalent (specific part number in manual).

🔧 Transmission

Standard

Transmission Type:

CVT (Continuously Variable Transmission) with Polaris P-85 Primary and P-90 Secondary clutches.

Optional

Gear Ratios:

Variable via CVT; manual specifies weights and spring adjustments for optimal engagement and peak RPM.

Features

Drive System:

Chaincase with helical cut gears, sealed for durability.

Gearcase Fluid:

Polaris AGL Synthetic Gearcase Lube or equivalent (specific SAE viscosity and capacity in manual).

Drive Belt Part Number:

Typically Polaris belt numbers like 3211084 or similar (exact number in manual).

📐 Dimensions

Exterior

Track Length:

163 inches

Track Width:

Likely 15 inches

Track Lug Height:

Typically 2.25 inches or 2.4 inches for this model.

Skis Stance:

Approximate 42-43 inches (check manual for exact measurement).

Weights

Dry Weight:

Around 470-480 lbs (check manual for exact figure).

Estimated Wet Weight:

Around 500-510 lbs (with fluids).

🛡️ Safety Features

Ratings

Safety Certification:

All applicable US and Canadian snowmobile safety standards for model year 2008.

Active Features

Braking System:

Hydraulic disc brake with single caliper and ventilated rotor.

Throttle Control:

Thumb throttle with adjustable tension.

Passive Features

Rollover Protection:

Not applicable to this type of vehicle in the traditional automotive sense, but structural integrity of chassis/tunnel is detailed.

Kill Switch:

Handlebar-mounted engine kill switch, often with a tether cord.

💡 Technology Features

Infotainment

Gauge Cluster:

Digital/analog combination display showing speed, RPM, fuel level, coolant temperature, odometer, trip meter, clock, and various warning lights.

Driver Assistance

No Driver Assistance:

No electronic driver assistance features such as ABS or traction control were common on performance snowmobiles of this era.

Connectivity

No Connectivity:

No integrated Bluetooth, GPS, or smartphone connectivity.

🔧 Maintenance

Service Intervals

Oil Change Interval:

Typically every 100-150 hours of operation or annually. (Specific recommendation in manual).

Drive Belt Inspection:

Every 50 hours, replace as needed or based on wear indicators.

Spark Plug Replacement:

Typically every 200-300 hours or annually. (Specific part numbers and gap in manual).

Gearcase Oil Change:

Annually or every 100-150 hours. (Specific capacity in manual).

Fluid Specifications

Coolant Type:

Ethylene glycol-based antifreeze, 50/50 mix with distilled water. (Specific Polaris part number or equivalent in manual).

Brake Fluid Type:

DOT 3 or DOT 4 hydraulic brake fluid. (Specific recommendation in manual).

Known Issues

Common Wear Items:

Drive belts, carbides, wear rods, suspension bushings, crank seals (common on older 2-strokes).

Carburetor Issues:

Gumming if fuel is not treated for storage, jetting changes for altitude adjustments.

Track Tension:

Improper track tension can lead to excessive wear on the track, drivers, and suspension components.

📚 Vehicle History

Brand Heritage

Polarisfamily:

Polaris Industries is a long-standing American manufacturer with a deep history in powersports, particularly snowmobiles, founded in 1954.

Model Evolution

Rmk Lineage:

The RMK (Rocky Mountain King) series represents Polaris's dedicated line of mountain and backcountry snowmobiles, focusing on lightweight design and deep snow capability.

Dragon Trim:

The 'Dragon' trim often denoted a higher-performance, feature-rich model within the RMK lineup, sometimes featuring specialized graphics and enhanced components.

Production

Manufacturing Location:

Polaris snowmobiles are primarily manufactured in the USA, at facilities in Minnesota and North Dakota.

🏆 Awards & Recognition

Recognitions

Industry Awards:

Specific awards for the 2008 RMK Dragon model may exist but are not readily recalled; generally, the RMK platform was highly regarded for its mountain performance.