Snowmobile Polaris 800 RMK / 800 Pro-RMK / 800 RMK (2010 year). Manual - part 22

89

MAINTENANCE

Lights

When servicing a halogen lamp, avoid touching the lamp with bare fin-
gers. Oil from your skin leaves a residue, causing a hot spot that will 
shorten the life of the lamp. If fingers do touch a lamp, clean it with 
denatured alcohol.

Headlight Lamp Replacement

1. Peel back the foam shield covering the headlight assembly.

2. Remove the wire harness connector from the back of the headlight.

3. Grasp the bulb housing and turn it counter-clockwise to remove the 

bulb.

4. Apply dielectric grease to the socket and install the new bulb. 

Rotate the bulb 1/4 turn clockwise to secure it.

5. Reinstall the connector to the back of the headlight.

6. Secure the foam shield.

Taillight/Brake Light Replacement

The taillight assembly is not serviceable. If the light fails to operate 
properly, replace the entire taillight assembly.

90

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 dealer immediately. Do not 
operate the snowmobile until repairs have been made. 

All clutch maintenance and repairs must 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 lubri-
cate clutch bushings.

Clutch Alignment Offset

Clutch alignment offset is important for maintaining optimum perfor-
mance. See your dealer for service and adjustments. A special tool is 
required to check for proper alignment.

91

MAINTENANCE

Clutch System

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 Drive Belt Troubleshooting on page 109.

Always carry a spare drive 
belt. Store the spare belt in 
the belt clip located under 
the left side 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.

92

MAINTENANCE

Clutch System

Drive Belt Deflection

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

Place a straight edge (1) on the 
belt and apply downward pressure 
while measuring at point 2. This 
measurement should be 1 1/4 
inches (3.2 cm).

Drive Belt Adjustment

1. Loosen the 7/16-inch jam nut on the belt width adjuster.

2. Using a 1/8-inch Allen wrench, turn the set screw inward (clock-

wise) to increase the distance between the sheaves or outward 
(counter-clockwise) to decrease the distance.

3. Tighten the jam nut.

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