Segment:
Deep powder and mountain riding snowmobile.
Key Competitors:
Arctic Cat M-series, Ski-Doo Summit, Yamaha Apex Mountain (comparable era models).
Rmk Design Philosophy:
Designed for extreme maneuverability in deep snow with a focus on rider-forward ergonomics and long track for flotation.
Engine:
Detailed disassembly, assembly, inspection, and repair of the 600cc Liberty twin-cylinder engine, including top-end, bottom-end, lubrication, cooling, and ignition systems.
Fuel System:
Carburetor tuning, cleaning, and overhaul; fuel pump operation and testing; fuel tank and lines inspection.
Drive System:
Primary and secondary clutch inspection, adjustment, and replacement; belt inspection and replacement; chaincase inspection, lubrication, and adjustments.
Suspension:
Front and rear suspension component inspection, lubrication, and replacement; shock absorber servicing; torque specifications for suspension fasteners.
Steering:
Handlebar assembly, steering post, steering linkage inspection and adjustment.
Brakes:
Hydraulic brake system diagnosis, caliper service, master cylinder overhaul, brake pad replacement, and fluid bleeding procedures.
Electrical:
Wiring diagrams, ignition system testing (CDI, spark plugs), lighting, starter system, and sensor diagnostics.
Body And Chassis:
Body panel removal and installation, seat servicing, track and tunnel inspection, and general chassis component maintenance.
Maintenance:
Regular scheduled maintenance, including engine oil changes, coolant checks, belt inspections, clutch cleaning, and lubrication points.
Troubleshooting:
Diagnostic flowcharts and symptom-based troubleshooting guides for common mechanical and electrical issues.
Repair:
Step-by-step repair instructions for virtually all components and systems of the snowmobile.
Rebuilds:
Complete engine and transmission overhaul procedures, including detailed specifications for wear limits and assembly tolerances.
Adjustments:
Clutch, brake, and throttle cable adjustments; suspension settings.
Depth:
Full factory level detail, suitable for both experienced mechanics and DIY enthusiasts undertaking complex repairs and diagnostics.
Print Readability:
High-resolution, designed for clear printing of all diagrams, illustrations, and text.
Binding Recommendation:
Printable in sections or as a complete booklet for workshop use.
Paper Recommendation:
Standard paper for digital printing; consider heavier stock for workshop durability.
Engine Type:
Liberty 600 Twin
Cooling System:
Liquid-cooled
Bore X Stroke:
72.1 mm x 73.2 mm
Ignition System:
CDI (Capacitor Discharge Ignition)
Exhaust System:
Twin pipes with silenced muffler
Horsepower Estimated:
~115-120 hp (varies by tuning and specific model variant)
Carburetor Size:
Mikuni TM40 flat slide (dual)
Fuel Type Recommendation:
87 Octane Unleaded Gasoline
Fuel Capacity:
11.7 gallons (44.3 liters)
Crash Test Information:
Snowmobiles are not subject to the same crash test ratings as passenger vehicles; safety relies on rider skill and machine design.
Engine Kill Switch:
Tethered emergency stop switch.
Headlight:
Halogen headlight for visibility.
Taillight And Brakelight:
Integrated LED taillight/brakelight.
Display Type:
Analog gauges (speedometer, tachometer) and indicator lights.
Storage:
Under-seat storage compartment.
Engine Management:
CDI ignition system with basic engine control.
Battery Charging:
12V battery system with alternator for charging.
Initial Break In:
First 25 hours: follow specific break-in procedure (refer to owner's manual for exact details, typically involves varied RPM operation).
Engine Oil Change:
Recommended every 100 hours or annually (refer to manual for exact oil type and capacity).
Clutch Maintenance:
Inspect primary and secondary clutches every 50-100 hours for wear, proper belt alignment, and cleanliness.
Track Tension:
Check and adjust track tension every 50-100 hours or as needed.
Engine Oil Type:
Polaris Synthetic 2-Cycle Snowmobile Oil (or equivalent API TC-W3 certified oil)
Coolant Type:
Ethylene Glycol based antifreeze mixture (50/50)
Chaincase Oil:
Polaris Synthetic Chaincase Lubricant (or equivalent SAE 80W-90 gear oil)
Brake Fluid Type:
DOT 4 Hydraulic Brake Fluid
Clutch Wear:
Clutch components, particularly the secondary roller arms and bushings, can wear over time, affecting performance. Regular inspection and lubrication are key.
Reeds:
Cracked or worn reed petals can impact engine performance and cause starting issues. The manual provides inspection and replacement procedures.
Suspension Bushings:
Wear in suspension pivot bushings can lead to sloppy handling. Replacement is a common maintenance item.
Polaris Heritage:
Polaris Industries is a long-standing American manufacturer known for its snowmobiles, ATVs, and UTVs, with a strong emphasis on innovation and off-road performance.
Rmk Lineage:
The RMK (Rear Mount Intercooler) line has been Polaris's flagship mountain snowmobile platform for years, continually evolving to meet the demands of deep snow and challenging terrain.
Model Year Significance:
The 2004 model represents a mature iteration of the RMK platform, benefiting from prior design refinements.
