Snowmobile Polaris Trail RMK (2010 year). Manual - part 20

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MAINTENANCE

Brakes

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Hydraulic Brake Inspection

Inspect the brake lever reserve before each use of the snowmobile. See 

page 45.
Brake pads must be replaced when the brake pad material becomes thin-

ner than the backing plate (approximately 1/16 inch/1.5 mm). A kit is 

available for replacing brake pads. See your dealer.

WARNING! Brake failure during operation can result in serious injury or death. 

Properly functioning brakes are vital to your safety. Be sure the brake pads do 

not drag on the disc and that brake lever travel is not excessive. Always replace 

brake pads when the brake pad material becomes thinner than the backing plate 

(approximately 1/16 inch/1.5 mm).

Brake Components

1. Brake Caliper
2. Chaincase
3. Brake Disc
4. Backing Plate
5. Brake Pad Material 

(Replace when thickness is 

less than 1/16 inch/1.5 mm)

1

2

3

4

5

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MAINTENANCE

Brakes

Brake Fluid

WARNING! After opening a bottle of brake fluid, always discard any unused 

portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it 

rapidly absorbs moisture from the air. The moisture causes the boiling 

temperature of the brake fluid to drop, which can lead to early brake fade and 

the possibility of accident or severe injury.

The brake fluid level can be seen through a plastic sight glass in the 

brake reservoir. If the fluid is sufficient, the sight glass will be black. If 

the sight glass is any color other than black, add brake fluid.
Keep the master cylinder cover free of dirt and debris. The vent slits 

allow for diaphragm movement, and if they become plugged, movement 

of brake fluid below the diaphragm may be restricted, altering brake 

function.
We recommend the use of Polaris DOT 4 high temperature brake fluid. 

See page 109 for the part numbers of Polaris products.

NOTICE: Brake fluid will damage decals, paint and some plastics. Always wipe 

up spills immediately.

Replace brake fluid at least every two years.

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MAINTENANCE

Brakes

Bleeding the Hydraulic Brake System

Air in the hydraulic brake system will cause spongy brake lever action. 

Bleed the system before operating the snowmobile.

WARNING! Operating the vehicle with a spongy brake lever can result in loss of 

brakes, which could cause an accident and lead to serious injury or death. 

Never operate the vehicle with a spongy-feeling brake lever.

During the bleeding procedure, keep the brake handle as level as possi-

ble. The reservoir must be in this position to minimize the possibility of 

air entering the system through the reservoir vent.
1. Remove brake master cylinder reservoir cover and gasket.
2. Fill the master cylinder reservoir to between the MIN and MAX 

marks or 1/4-5/16 inch (.6-.8 cm) below the lip of the reservoir 

opening. Reinstall the gasket and cover.

3. Slip a rubber tube over the ball of the bleeder valve and direct the 

flow of fluid into an approved container.

4. Squeeze the brake lever a full stroke. Then unscrew the bleeder 

valve 3/4 of a turn to release air.

5. Close the bleeder valve and release the brake lever.
6. Repeat steps 4 and 5 until fluid flows from the bleeder valve in a 

solid stream free of air bubbles.

WARNING! Overfilling the master cylinder leaves no room for fluid expansion 

and may cause the brakes to lock, resulting in serious injury or death. Always 

add brake fluid to the fill line as recommended.

7. After bleeding is complete, refill the reservoir to the proper level.
8. Reinstall the gasket and cover.

84

MAINTENANCE

Lights

Headlight Adjustment

The headlight may be adjusted for vertical aim using the following pro-

cedure:
1. Place the snowmobile on a level surface with the headlight approxi-

mately 25 feet (7.6 m) from a wall.

2. Measure the distance from the floor to the center of the headlight 

and make a mark on the wall.

3. Start the engine and turn the headlight switch to high beam.
4. Observe the headlight aim. The most intense part of the headlight 

beam should be aimed two (2) inches (5.1 cm) below the mark 

placed on the wall in step 4. 

Tip: Rider weight must be included on the seat.

5. Turn the adjustment nut, located inside the hood, just below the 

headlamp opening. Turn the knob in or out as needed for proper 

aim.

2 in. (5.1 cm)

Lamp Center Height

25 ft. (7.6 m)

Adjustment 

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