Polaris 600 Rush-Pro-R manual

PMS 419 Modifications to this snowmobile are not recommended and may result in voided warranty coverage. Please read the warranty section of this manual carefully . IMPORT ANT NOTICE T O OWNER Snowmobile Owner's Manual for Maintenance and Safety 600 RUSH ® PRO-R 800 RUSH ® PRO-R[...]

W ARNING Read, understand, and follow all of the in structions and safety precautions in this manual and on all produ ct labels. Failure to follow the safety precautions could result in serious injury or death . W ARNING The engine exhaust from this p roduct contains chemicals known to the S tate of California to cause cancer , birth defects or oth[...]

1 WELCOME Thank you for purchasing a POLARIS vehicle, and welcome to our world-wide family of POLARIS enthusiasts. Be sure to visit us online at www .polaris.com for the latest news, new product introductions, upcoming events, career opportunities and more. Here at POLARIS we proudly produce an exciting line of utility and recreational products. ?[...]

2 POLARIS, PERC, PRO-RIDE and RUSH are registered trademarks of POLARIS Industries Inc. Copyright 2013 POLARIS Sales 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 discrep- ancies[...]

3 T ABLE OF CONTENTS Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 This section contains helpful information for owners and drivers and illustrates the location of important identification numbers that should be recorded in the owner's manual. Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 T[...]

4[...]

5 INTRODUCTION Import ant Notes for Owners and Drivers After reading this manual, store it in the snowmobile for convenient ref- erence. It should remain with the snowmobile when the snowmobile is sold. Some of the illustrations and photos used in this manual are general rep- resentations. Y our model may differ . Follow the maintenance program out[...]

6 INTRODUCTION Preservation of the Environment POLARIS is committed to supporting an environmental education cam- paign. W e encourage state and provincial governments across the snow- belt to adopt rigorous safety training programs that encourage protection of our environment, including wildlife and vegetation. Snowmobile clubs and other or ganiza[...]

7 INTRODUCTION V ehicle Identification Numbers Record your snowmobile 's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Y our key can be duplicated only by mating a POLARIS key blank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced. [...]

8 SAFETY Operator Safety The following signal words and symbol s appear througho ut this manual and on your vehicle. Y our safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symb ol ind icates a potential personal injury haza rd. DANGER A DANGER indicates a haz[...]

9 SAFETY Operator Safety Follow the recommended maintenance program beginning on page 81 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals. Driving a snowmobile requires your full attention. DO NOT drink alcohol or use drugs or medications before or while dr[...]

10 SAFETY Operator Safety St ay Clear of T rack Y our snowmobile is propelled by a revolving track that must be partially exposed for proper operation. Do not stand on the plastic flap. W ARNING! Serious injuries may result if hands, feet, or clothing become entangled in the track. Be alert when riding, and remain properly seated to st ay clear of [...]

11 SAFETY Operator Safety Riding App arel Helmet W earing a helmet can prevent a severe head injury . Whenever riding a POLARIS vehicle, always wear a helmet that meets or exceeds estab- lished safety standards. Approved helmets in the USA and Canada bear a U.S. Department of T ransportation (DOT) label. Approved helmets in Europe, Asia and Oceania[...]

12 SAFETY Operator Safety Disabled Operators Safe operation of this rider -active vehicle requires good judgement and physical skills. Operators with cognitive or physical disabilities have an increased risk of loss of control, which could result in serious injury or death. Survival Prep aration For your safety , always ride in a group of other sno[...]

13 SAFETY Operator Safety Rider Cap acity This snowmobile is designed for a single rider only . Never carry a pas- senger on this snowmobile. Excessive Speed W ARNING! High speed driving, especially at night, could result in serious injury or death. Always reduce speed when driving at night or in inclement weather . Always observe all state and lo [...]

14 SAFETY Operator Safety Driver Awareness Slow down when traveling near poles, posts, or other obstacles. Be especially alert if you're snowmobiling after dark. Always be on the alert for wire fences. Single strands are especially dangerous, since there may be a great distance between posts. Guy wires on utility poles are also difficult to di[...]

15 SAFETY Operator Safety A valanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain: • T ake an avalanch e cl ass • T ravel with experienced people • T ravel on designated trails • Make sure each person is equipped with a shovel, probe and avalanche beacon. Y ou don't have to be sno[...]

16 SAFETY Operator Safety Ice and Snow Build-up W ARNING! Ice and snow build-up may interf ere with the steering of your snowmobile, resulting in serious injury or death. Ke ep the und erhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right s[...]

17 SAFETY Operator Safety Driving Downhill When riding downhill, shift your weight to the rear of the snowmobile and reduce your speed to a minimum. Apply just enough throttle to keep the clutch engaged, allowing the engine's compression to help slow the snowmobile and keep it from rolling freely downhill. W ARNING! When driving on lon g downh[...]

18 SAFETY Operator Safety Drive Belt Do not operate the engine with the drive belt r emoved. Any servicing that requires operation without a belt must be performed by your dealer . NOTICE: Operation of the engine with the belt removed may result in injury or damage to the engine. Int ake Silencer Do not operate the engine with the intake silencer o[...]

19 SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently , and even the most docile condi- tions may become dangerous if oper ators drive improperly . If you're new to snowmobiling, acquaint yourself with the snowmobile and with what it will and won't do under various conditions. Even seasoned driv- ers should sp[...]

20 SAFETY Operator Safety Windchill/T emperature Charts The following information is provided to help you determine when tem- peratures become dangerous for riding. WINDCHILL CHART (°F) WINDCHILL CHART (°C) Wind S peed in MPH Actual Thermometer Reading ( ° F) 40 35 30 25 20 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45 Equivalent T emperature ( ?[...]

21 SAFETY Safety Labels and Locations W arning labels have been placed on the snowmobile for your protection. Read and follow the instructions of the labels and other warnings on the snowmobile carefully . If any of the labels depicted in this manual differ from the labels on your snowmobile, always read and follow the instruc- tions of the labels [...]

22 SAFETY Safety Labels and Locations T rack W arning W ARNING St ay clear of track. Do not sit on seat back. Entangle- ment with the track or a fall from seat back may result in severe injury or death. No Passenger W arning/Fuel Recommendation Label W ARNING This vehicle is designed for operator only . NO P ASSENGER. Reverse W arning W ARNING Reve[...]

23 SAFETY Safety Labels and Locations Operation W arning W ARNING • T o avoid serious injury or death , read and understand all warn - ings and th e Owner's Ma nual before operation. If manual is missing, contact a POLARIS dealer for a replacement. • This vehicle is cap able of high speeds. Buried objects or uneven terrain can cause lo ss [...]

24 FEA T URES 8 13 5 6 7 12 11 2 1 3 4 10 9 1. Nosepan 2. Skis 3. Front Bumper 4. Hood 5. Headlight 6. W indshield (accessory) 7. Handlebar 8. Operator Seat 9. T a illight 10. Rear Bumper 11 . S n o w F l a p 12. Suspension 13. T rack 14. Side Panel 15. Side Panel Fasteners 16. T ool Kit/S torage Bag 15 14 16[...]

25 FEA TURES 1. Brake Lever 2. MFD Gauge 3. Ignit ion Switch 4. Engine Stop Switch 5. Throttle Control 6. Recoil St arter Handle 7. Parking Brake Lock 8. Handlebar Gr ip Warmer Switch 9. Thum bwar mer Switch 10. Electronic Reve rse Button 1 1. Mode/Set Switch 12. Headlight Dimmer Switch 3 4 5 6 2 1 11 10 12 78 9[...]

26 FEA T URES Adjust able Headlight s Move the headlight adjuster to the left to adjust the headlight beam upward. Move the adjuster to the right to adjust the beam down- ward. Up Down[...]

27 FEA TURES Fuel T ype Selection Whenever using ethanol, MTBE or other forms of oxygenated gaso- lines, the fuel type designation setting must be changed to “Et h” in the gauge. When using the recommended 91 non-ethanol gasoline, always select the “91-non” setting. Whenever in doubt of your fuel pur chase, use the “Eth” setting as a sa[...]

28 FEA T URES Detonation Elimination T echnology (DET) The DET system prevents damage to the engine from detonation by going into an engine protection mode whenever the DET system is active. When excessive detonation is detected, the check engine light will illuminate and you may notice decreased engine performance and RPM when the DET system is ac[...]

29 FEA TURES Detonation Elimination T echnology (DET) The most likely causes of severe detonation are outlined in the trouble- shooting table below . DET T roubleshooting Security System (Ignition Lock System) Y our snowmobile has an optional security function that can be activated by an authorized POLARIS dealer . If you have this feature activate[...]

30 FEA T URES Instrument Cluster The instrument cluster contains indicator lights and the rider infor - mation center . The information cen- ter can be controlled by either the MODE and SELECT buttons on the instrument cluster or by the MODE/ SET switch on the left handlebar . NOTICE: Certain products will damage the lens and other plastic sur- fac[...]

31 FEA TURES Instrument Cluster Indicators Check Engine Indicator This indicator appears if an EFI-related fault occurs. Do not operate the snowmobile if this warning appears. Serious engine damage could result. See your dealer . See page 44 for diagnostic code definitions. Over-T emperature Indicator This indicator illuminates to alert the operato[...]

32 FEA T URES Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster . The center displays vehicle speed, engine speed, odometer , resettable trip meters (2), total engine hours of operation, fuel level, engine tempera- ture and diagnostic display mode. Setting changes must be made with the eng[...]

33 FEA TURES Instrument Cluster Rider Information Center 1. Information Display Area - This area displays either engine speed or vehicle speed (whichever is not displayed in the speed display), engine temperature and maximum vehicle speed. T o change the dis- play , see page 34. 2. Speed Display - The speed display area displays either vehicle spee[...]

34 FEA T URES Instrument Cluster Rider Information Center Spe ed Display Area The speed display area displays either vehicle speed or engine speed. V ehicle speed is displayed in either miles per hour (MPH) or kilometers per hour (km/h). Engine speed is displayed in revolutions per minute (RPM). 1. T o change which item displays, first make sure th[...]

35 FEA TURES Instrument Cluster Rider Information Center Odometer/Engine Hour Display Area This area displays the odometer , T rip A meter , T rip B meter and engine hours meter . The odometer displays the total distance traveled by the vehicle since manufacture. Each trip meter records the distance traveled by the vehi- cle on a trip if the meter [...]

36 FEA T URES Instrument Cluster Rider Information Center St andard/Metric Display The odometer and temperature displays can be viewed in either standard or metric units of measurement. Both displays change if units are changed. The new settings will remain until changed by the operator . Change Method 1 1. Pr ess and r elease the MODE button or MO[...]

37 FEA TURES Instrument Cluster Rider Information Center Security System (Ignition Lock Syste m) This system is an optional feature and will not function until it has been activated by your authorized POLARIS dealer . If you have this feature activated, you can lock the ignition to prevent unauthorized use when leaving the snowmobile unattended. A [...]

38 FEA T URES Instrument Cluster Rider Information Center Security System (Ignition Lock Syste m) First T ime Use of Y our Security System Perform all tasks in the or der shown if you wish to activate and use the optional security system. T ASK 1: Activate the security system See your authorized POLARIS dealer to have the optional security system f[...]

39 FEA TURES Instrument Cluster Rider Information Center Security System (Ignition Lock Syste m) First T ime Use of Y our Security System T ASK 3: Unlock the System 1. When the engine is runn ing, the display will alternate between SECURE ON and ENTER CODE. Wait until ENTER CODE displays, then press and release SEL to advance the digit. When “0?[...]

40 FEA T URES Instrument Cluster Rider Information Center Security System (Ignition Lock Syste m) Locking the System Wit h Y our Personal Security Code 1. S tart the engine and lock the parking brake. 2. Press and hold the MODE and SEL buttons for 3 seconds, then release. SECURE OFF should be displayed. If no t, repeat this step. 3. W ait until ENT[...]

41 FEA TURES Instrument Cluster Rider Information Center Security System (Ignition Lock Syste m) Unlocking the System With Y our Personal Security Code 1. When the engine is running, the display will alternate between SECURE ON and ENTER CODE. W ait until ENTER CODE displays, then press and release SEL to advance the di git. When the fi rst digit o[...]

42 FEA T URES Instrument Cluster Rider Information Center Security System (Ignition Lock Syste m) Changing to a New Security Code Any time you wish to change your curre nt security code to a new code, perform T ASK 2 through T ASK 4 of the First Time Use of Y our Secu- rity System procedure beginning on page 38. Instead of using the fac- tory defau[...]

43 FEA TURES Instrument Cluster Rider Information Center Diagnostic Display Mode The diagnostic display mode is for informational pu rposes only . Please see your POLARIS dealer for all major repairs. The diagnostic mode is accessible only when the check engine warning indicator is illuminated and a diagnosti c code is active. Do not stop the engin[...]

44 FEA T URES Instrument Cluster Rider Information Center Diagnostic Display Code Definitions Open Load: There is a break in the wires that lead to the item listed in the chart (injector , fuel pump, etc.), or the item has failed. Short-to-Gr ound: The wire is shorted to ground between the electronic control unit and the item listed in the chart. S[...]

45 FEA TURES Instrument Cluster Rider Information Center Diagnostic Display Code Definitions Diagnostic Codes Component Condition SPN FMI ECU Memory Checksum/CRC Error 628 13 Injector 1 (MAG) (Port Injector) Driver Circuit Open/Grounded 651 5 Driver Circuit Short to B+ 3 Injector 2 (PTO) (Port Injector) Driver Circuit Open/Grounded 652 5 Driver Cir[...]

46 THE PERFECT FIT Suspension Quick Set-Up Guide The suspension on your RUSH is incredibly easy to adjust to your weight and riding style. Just remember three simple steps: 1. Set up rear shock spri ng preload for rider weight. 2. Adjust the r ear spring to tune vehicle balance (ski pressure and weight transfer). 3. Adjust shock clickers to tune ri[...]

47 THE PERFECT FIT Suspension Quick Set-Up Guide Step 2: Adjust the rear spring to tune vehicle balance. After the initial test ride, make adjustments to the rear shock spring to improve vehicle balance. Increasing preload will increase ski pressure and result in less weight transfer , flatter cornering and more precise steering response. Decreasin[...]

48 THE PERFECT FIT Suspension Quick Set-Up Guide Accessory rear shock springs are available for riders of dif ferent weights. A corresponding gauge is available for each spring type. The gauge provided with your snowmo bile is calibrated for the stock spring, which should be used by most riders. Do not change springs unless your weight is at the ve[...]

49 THE PERFECT FIT Suspension Quick Set-Up Guide POLARIS recommends that riders use this Quick Set-Up Guide to make any adjustments for rider weight and trail conditions. If additional tun- ing is needed after you have exhausted all possible adjustments to the rear shock spring and clicker , refer to the information on the following pages of this m[...]

50 THE PERFECT FIT Front Suspension Adjustment s Independent Front Suspension (IFS) Factory settings, combined with user adjustments to the rear shock spring, should be all that’ s necessary to provide the best riding experi- ence for most riders. If all rear shock spring adjustments have been exhausted and rider weight is at the very high or ver[...]

51 THE PERFECT FIT Front Suspension Adjustment s IFS Shock Spring Preload Increasing spring preload will increase ski- to-ground pressure. Decreasing spring pre- load will decrease ski-to-ground pressure. When adjusting, be sure the springs on both the left and right sides of the machine are at the same adjustment. Always perform shock spring prelo[...]

52 THE PERFECT FIT Front Suspension Adjustment s IFS Shock Compression Damping Make adjustments to the shock clickers to control bottoming. Make the adjustments in 1-to-2-click increments, then test ride. Repeat the adjust- ment until the desired result is achieved. TIP: Initially , heavier riders ma y want to set the shock clickers 2-4 clicks high[...]

53 THE PERFECT FIT Rear Suspension Adjustment s Rider weight, riding style, trail conditions, and vehicle speed all af fect suspension action. Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. However , all sus- pension designs and adjustment s involve a co mp romise, or t[...]

54 THE PERFECT FIT Rear Suspension Adjustment s Front T rack Shock Compression Damping Make adjustments to the shock clicker to control bottoming. Make the adjustments in 2-click incre- ments, then test ride. Repeat the adjustment until the desired result is achieved. TIP: Initially , hea vier ri ders may want to set the shock clickers 2-4 clicks h[...]

55 THE PERFECT FIT Rear Suspension Adjustment s Rear Shock Spring Preload Settings Make adjustments to the rear shock spring to tune vehicle balance. Always perform shock spring preload adjustments with the weight of the vehicle removed from the shoc k and with the shock at full extension. Increasing preload will increase ski pressure and result in[...]

56 THE PERFECT FIT Handlebar Adjustment s Handlebar Position 1. Loosen the four bolts on the bottom of the adjuster block. If necessary , pry the blocks apart with a screw- driver . 2. Adjust the handlebar for- ward or rearward to the desired position. 3. T ighten the bolts. T orque the bolts to 13-16 ft. lbs. (18-22 Nm). Handlebar Angle 1. Loosen [...]

57 THE PERFECT FIT Accessories POLARIS offers a wide range of accessories for your snowmobile to help make each ride more enjoyable. Use only POLARIS parts and accessories on your POLARIS snowmo- bile. Use of unapproved parts and accessories may result in: • Non-compliance with government/industry requirements • V oiding of warranty • Injury [...]

58 THE PERFECT FIT T raction Product s Stu d s The track is not warranted by POLARIS if studs have been installed. T rack warranties are also void if track damage or failure results from the use of any non-POLARIS traction products. Use only POLARIS- approved traction products on your snowmobile. If you choose to install studs, stud length must not[...]

59 THE PERFECT FIT T raction Product s Carbide Skags A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and t o prevent ski wear caused by contact with roads and other bare terrain. Use carbide skags with studded tracks to help maintain proper vehicle s teering and control. See page 1 1 1. If your s[...]

60 PRE-RIDE INSPECTIONS Pre-Ride Checklist Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined on the refer - enced pages. Item See Page Drive Belt Condi tion 101 S teering System 65 Recoil Rope 65 Coolant Leve l 91 Chaincase Oil Level 86 Injection Oil Level 73 Parking Brak[...]

61 PRE-RIDE INSPECTIONS Pre-Ride Suspension Inspection Loose nuts and bolts can reduce your snowmobile's reliability and cause needless repairs and down time. Before beginning any snowmobile trip, a visual inspection will uncover potential problems. Check the follow- ing items on a weekly basis or before any long trip. Item See Page Check susp[...]

62 PRE-RIDE INSPECTIONS Before St arting the Engine Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start the engine without checking all vehicle components to be sure of proper operation. W ARNING! Operating the vehicle with worn, damaged, or malfunctioning components could result in seriou[...]

63 PRE-RIDE INSPECTIONS Before St arting the Engine Brakes Always check the following items for proper operation before starting the engine. Brake Lever T ravel Squeeze the brake lever . It should move no closer to the handgrip than 1/2 inch (1.3 cm). A smaller distance indi- cates low brake fluid level or air in the hydraulic system. Refer to the [...]

64 PRE-RIDE INSPECTIONS Before St arting the Engine Parking Brake Lever Lock Use the parking brake lever lock only when you want the snowmobile to remain stationary; for example, when parked on an incline for a period of five minutes or less. 1. Brake Lever 2. Parking Brake Lever Lock 3. Master Cylinder Reservoir/ Cover 4. Fluid Level Indicator Loc[...]

65 PRE-RIDE INSPECTIONS Before St arting the Engine Steering System W ARNING! Ice and snow build-up may interf ere with the steering of your snowmobile, resulting in serious injury or death. Keep the und erhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with fu[...]

66 PRE-RIDE INSPECTIONS S t art the Engine and Check Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never engage the starter when the engine is running. Never start the engine without checking all vehicle components to be sure of proper operation. See Be fore Starting the Engine beginning on page[...]

67 OPERA TION S t arting the Engine NOTICE: Engaging the starter when the engine is run ning WILL result in serious engine damage, especially if the snowmobile is in reverse. Never engage the starter when the engine is runni ng. 1. T u rn the key to the ON position. 2. Pull the engine stop switc h up to the RUN position. 3. If equipped with electri[...]

68 OPERA T ION Break-In Period Engine Break-In Always follow these recommended break-in procedures for new or rebuilt engines. The first tank of fuel is considered the break-in period for the engine. Premix the first tank of fuel and fill the oil reservoir as outlined below . Oil added to the fuel and oil injection systems will provide the necessar[...]

69 OPERA TION Break-In Period Engine Break-In Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts. Do not operate at full throttle or high speeds for extended periods during the fi rst three hours of use. V ary the throttle openings and vehicle spee ds to reduce friction on all close-fit- ting mac[...]

70 OPERA T ION T rack W arm-Up W ARNING! A loose track or flying debris could cause serious injury or death. S tand clear of the front of the sno wmobile and the moving tra ck. Never hold the snowmobile up or stand be hind it while warming up the track. Do not use excessive throttle during warm-up or when the track is free-hanging. Use a stable rea[...]

71 OPERA TION Fuel Gasoline is highl y flammable and explosive under certain conditions. • Always exercise extreme caution w henever handling g asoline. • Always refuel outdoors or in a well-ventilated area. • Always turn off the engine before refueling. • Do not overfill the tank. Do not fill the tank neck. • Do not smoke or allow open f[...]

72 OPERA T ION Fuel Recommendation For peak performance, POLARIS recommends the use of 91 octane fuel or higher . Although 87 octane fuel is usable, some engine performance will be lost and fuel economy will decrease. Do not use lower than 87 octane fuel. Do not use fuel containing mo r e than 10% ethanol. Never use E85 fuel in your snowmobile . NO[...]

73 OPERA TION Oil Low Oil Level Always maintain the oil level between the “add” mark and the bottle neck. Do not fill the bottle neck. See page 68 for oil recommendations. 1. Immediately stop the engine if the low oil indicator light comes on. 2. Open the left side panel. 3. V iew the oil level in the oil bottle. 4. Add oil as needed before ope[...]

74 OPERA T ION Engine St op Switch Push down on the engine stop switch (X) to ground out the ignition and stop the engine quickly . Pull the switch up to the ON position to allow restart- ing. Throttle Safety Switch The throttle safety switch is designed to stop the engine whenever all pressure is removed from the throttle lever and the throttle ca[...]

75 OPERA TION Throttle Lever W ARNING! An improperly functioning thro ttle lever may cause erratic snowmobile behavior a nd loss of control, wh ich could resu lt in serious injury o r death. If the throttle lever does not work properly , DO NOT start the engine. If the engine stops abruptly when the throttle lever is released: 1. T u rn the ignitio[...]

76 OPERA T ION Emergency S topping The following chart lists methods for stopping the snowmobile in the event of an emergency . See page 74 for more information about the engine stop switch and throttle safety switch. SYSTEM WHA T IT DOES Ignition Switch Interrupts ignition circuit Brake Slows jackshaft Engine S top Switch Interrupts ignition circu[...]

77 OPERA TION Electronic Reverse (PERC) Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Da mage will oc cur to the chain case if shifting is attempted when the engine is operating above idle sp eed . • Shift to or from reverse only when the snowmobile is stopped and when engine spee[...]

78 OPERA T ION Electronic Reverse (PERC) Engaging Reverse 1. S top the snowmobile and leave the engine idling. 2. Make sure the area behind your vehicle is clear . 3. Push the yellow reverse button on the left-hand control for one sec- ond, then release. The engine will automatically reduce RPM and start a reverse rotation. A flashing reverse light[...]

79 OPERA TION Daily St orage At the end of each ride, park the sn owmobile on a level surface and sup- port it at the rear with an appropriate track stand. The track should be suspended approximately 4 inch es (10 cm) of f the ground. Remove the key and cover the snowmobile. To w i n g For your safety , do not attempt to use a tow hitch until you&a[...]

80 MAINTENANCE Emission Control Information Any qualified repair shop or qualified person may maintain, replace, or repair the emission control devices or systems on your snowmobile. Emission Control Label Y our snowmobile is equipped at the time of sale with an emission con- trol information (ECI) label and a factory-installed emissions informa- t[...]

81 MAINTENANCE POLARIS Recommended Maintenance Program T o ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as out- lined in this manual. Record maintenance and service in the Mainte- nance Log beginning on page 133. The recommended maintenance schedul e on your snowmobile c[...]

82 MAINTENANCE Periodic Maintenance Interval T able The following chart is a guide based on average riding conditions. Y ou may need to increase frequency based on riding conditions. When inspection reveals the need for rep lacement parts, always use genuine POLARIS parts, available from your POLARIS dealer . I - Inspect (clean, adjust, tighten, lu[...]

83 MAINTENANCE Periodic Maintenance Interval T able Item See Page Frequency 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi. (3200 km) Pre- Season BRAKES Hose Routing -- II II Hose Condition -- II II Fluid Leaks -- II II Brake Pads 96 II II Brake Disc -- II II Parking Brakes 64 II II Brake System 63, 96 I Brake Fluid 97 I FUEL MANAGEME[...]

84 MAINTENANCE Periodic Maintenance Interval T able I - Inspect (clean, adjust, tighten, lubricate, replace if necessar y) C - Clean R - Replace L - Lubricate Bolt T orque Inspection T o maintain proper chassis performance, see your POLARIS dealer for a bolt torque inspection every 1000 miles (1600 km). Item See Page Frequency 150 mi. (240 km) 500 [...]

85 MAINTENANCE Hood/Side Panel The hood and side pa nels of the snowmobile protect the operator from moving parts. Never oper- ate a snowmobile with the side panels open or remove d. Always ensure that the hood and side panels are securely in place before starting the engine. T o open a side panel, rotate the two 1/4-turn fasteners at the upper edg[...]

86 MAINTENANCE Lubrication Chaincase Oil Check and change the chaincase oil at the intervals outlined in the main- tenance charts beginning on page 81. Maintain the oil level at the top of the fill plug hole. POLARIS recommends the use of POLARIS Syn- thetic Chaincase Lube. See page 115 for the part numbers of POLARIS products. Oil Level 1. Positio[...]

87 MAINTENANCE Int ake Filters The intake foam filters limit snow ingestion into the intake system. When operating in loose powder snow , check the foam filters periodically to remove any accumulation of snow . Fuel Pump All fuel pump service must be performed by an authorized POLARIS dealer . Do not attempt to service the fuel pump. Fuel Filter/Fu[...]

88 MAINTENANCE Spar k P l u g s Sp ark Plug Recommendations A new engine can cause temporary spar k plug fouling due to the preser - vative added during the assembly process. A void prolonged idle speeds, which cause plug fouling and carbonization. Change the spark plug s at the interv a l s outlined in the Periodic Mainte- nance T able beginning o[...]

89 MAINTENANCE Spar k P l u g s Sp ark Plug Insp ection Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color . CAUTION! A hot exhaust system and engine can cau[...]

90 MAINTENANCE Oil Lines Inspect oil line condition every 1000 miles (1600 km). Oil Filter Please see your dealer for replacement of the in-line oil filter every 2000 miles (3200 km) as outlined in the maintenance charts beginning on page 81.[...]

91 MAINTENANCE Cooling System Coolant The coolant supplied in the system at the factory is a 50/50 mixture of ethylene-glycol and distilled water , which will provide adequate freeze protection under most conditions. If the vehicle will be stored or oper - ated at extremely low temperatures, greater protection may be require d. Please see your POLA[...]

92 MAINTENANCE Cooling System Engine Overheating The over-temper ature indicator on the instrument cluster will illuminate when the engine is overheating. The indicator will flash when engine temperature reaches critical levels. Illuminated Indicator T ake action to cool the engine: • Drive in loose snow . • V iew the coolant level. Do not open[...]

93 MAINTENANCE Cooling System Bleeding the Cooling System CAUTION! S team and hot liquids will cause burn s to your skin. Never bleed the cooling system or remove the pressure cap when the engine is warm or hot. Use of a non-standard pressure cap will not allow the recovery system to function properly . If the pressure cap needs replacement, contac[...]

94 MAINTENANCE Exhaust System Check the exhaust system for wear or damage at approximately 2000 miles (3200 km). Always allow the engine and exhaust system to cool completely before inspecting. CAUTION! Hot exhaust system part s can cause burns. Allow adequate time for the exhaust system to cool. Never perform this procedure with the engine running[...]

95 MAINTENANCE Drive Chain T ension Check drive chain tension at the intervals outli ned in the maintenance charts beginning on page 81 and before each long trip. 1. Remove the side panels. 2. Rotate the driven clutch coun- ter -clockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake l[...]

96 MAINTENANCE Brakes Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 63. Brake pads must be replaced when the brake pad material becomes thin- ner than the backing plate (approximately 1/16 inch or 1.5 mm). A kit is available for replacing brake pads. See your dealer . W ARNING! Brake failure [...]

97 MAINTENANCE Brakes Brake Fluid 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. Replace brake fluid at least every two years with POLARIS DOT 4 high temperature brake fluid. See pag[...]

98 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. W ARNING! Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an accident and lead to serious in jury or death. Never operate [...]

99 MAINTENANCE Light s 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. Remove the wire harness connector from the back of the headlight[...]

100 MAINTENANCE Clutch System Periodically inspect clutch sheaves for damage, wear or belt residue. T o maintain optimum performance, clean with non-oil based cleaners such as isopropyl alcohol. W ARNING! If you become aware of higher than normal clutch engagement or an unusual vibration or shift pattern, see your dealer immediatel y . Do not opera[...]

101 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 124. Always carry a spare drive belt. S[...]

102 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 nu t on the belt [...]

103 MAINTENANCE Clutch System Drive Belt Removal NOTICE: Do not attempt to remove the dri ve belt after opera ting in reverse. The snowmobile must be stop ped after forward moti on to prevent damage to components during belt removal. Rotate the driven clutch counte r- clockwise 1/4 turn by hand to ensure forward engagemen t be fore attempti ng to r[...]

104 MAINTENANCE Clutch System Drive Belt Inst allation 1. Drop the drive belt over the drive clutch and pull back the slack. The belt cord line should be flush with, or slightly above, the outer cir - cumference of the driv en clutch sheaves. The belt will seat itself in the driven clutch during the break-in period. Adjust the belt ride-out after t[...]

105 MAINTENANCE T rack Maintenance T rack Inspection W ARNING! Broken track rods can cause a rotating track to come off the snowmobile, which could cause seri ous injury or death. Never operate with a damaged track. Never rotate a damaged track under power . 1. Using a hoist, safely lift and support the rear of the snowmobile off the ground. 2. Rot[...]

106 MAINTENANCE T rack Maintenance W ARNING! Moving part s can cut and crush body parts. When performing the checks and adjustments recommended on the following pages, stay clear of all moving part s. Never perform track measur ement or adjustme nts with the engine running. T rack T ension T rack adjustment is critical for proper handling. Always m[...]

107 MAINTENANCE T rack Maintenance T rack T ension 5. Check for specified slack between the wear surface of the track clip and the plastic slider . Refer to the Track T ension Data Chart on page 106. If the track needs adjustment: 6. Loosen the rear idler shaft bolt. 7. Loosen the locknuts. 8. T ighten or loosen the track adjus ting screws to provi[...]

108 MAINTENANCE T rack Maintenance T rack Alignment Periodically check that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. 1. Safely support t he rear of the snowmobile with the track off the ground. 2. S tart the engine and apply a small amount of throttle until the [...]

109 MAINTENANCE S teering System Front Suspension Inspection Each week, or before a long ride, check all steering system fasteners and tighten if necessary . X X X X[...]

110 MAINTENANCE S teering System Ski Alignment W ARNING! Improper ski alignment or adjust ment may cause loss of steering control, resulting in se rious injury or d eath. Do not attempt to change the ski alignment or camber adjustment. See your POLARIS dealer . 1. Place the handlebars in a straight-ahead position. 2. W ith only vehicle weight compr[...]

111 MAINTENANCE S teering System Ski Skags W ARNING! Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causing seri ous injury or death. See your dealer's studding chart fo r recommended skags. If you install longer or more aggressi ve carbide skags than the original equipment, it may also be ne cessary[...]

112 MAINTENANCE S teering System Rail Slide Wear Measure slide thickness at several points along the rail. Have your dealer replace the slide when it's worn down to the top of the wear limit indicator groove. Do not operate the snowmobile if slide thickness measures less than 7/16 inch (1.1 cm). Rear Suspension Lubricate the suspension pivot s[...]

113 MAINTENANCE Fall T une-Up For maximum performance, arrange for a fall service tune-up with your POLARIS dealer . His experienced and trained service technician will keep your snowmobile in peak operating condition. Matte Clear Coat Cleaning (if equipped) Matte finish products are prone to trapping dirt, oils and other contami- nants. POLARIS In[...]

114 MAINTENANCE Extended Storage Clutch and Drive System Remove the drive belt and store in a cool dry location. Do not lubricate clutch components, except the driven clutch shaft bushing as outlined in the Master Repair Manual. See your dealer . Engine Protection Proper preparation of the engine and fuel system is vital to the preven- tion of rust[...]

115 POLARIS PRODUCTS Part No. Description Engine Lu bricants 2870791 Fogging Oil (12 oz. Aerosol) 2877882 VES 2-Cycle Oil (qt./.95 l) 2877953 VES 2-Cycle Engine Oil (2 qt./1.9 l) 2877883 VES 2-Cycle Engine Oil (gal./3.8 l) 2877884 VES 2-Cycle Engine Oil (2.5 gal./9.5 l) Chaincase Lubrica nts 2873105 SCL - Synthetic Chaincase Lubricant (qt./.95 l) 2[...]

116 SPECIFICA T IONS 600 RUSH Cap acities and Dimensions Body Style PRO-RIDE Rider Capacity 1 Coolant Capacity 5 qts. (4.7 l) Chaincase Oil Capacity 9 oz. (266.2 ml) Fuel T ank Capacity 1 1 gal. (41.6 l) Gearcase Oil Capacity (oz./ml) N/A Height 46 inches (1 17 cm) Length 108 inches (274 cm) Oil Capacity (qts./l) 3.8 qts. (3.6 l) Designed W idth (i[...]

117 SPECIFICA T IONS 600 RUSH (Non-Electric St art Models) 600 RUSH (Electric St art Models) Clutching Chart AL TI TUDE Meters (Feet) Drive Clutch Shif t Weight Drive Clutch Spri ng Driven Clu tch Spr i ng Driven Helix Chaincase Gearing/ Pitch *Shaded cells indicate factory settings. 0-600 (0-2000) 10-64 (1321585) 120/310 Black (7043681) 130/180 P2[...]

118 SPECIFICA T IONS 800 RUSH Cap acities and Dimensions Body Style PRO-RIDE Rider Capacity 1 Coolant Capacity 5 qts. (4.7 l) Chaincase Oil Capacity 9 oz. (266.2 ml) Fuel T ank Capacity 1 1 gal. (41.6 l) Gearcase Oil Capacity (oz./ml) N/A Oil Capacity (qts./l) 3.8 qts. (3.6 l) Height 46 inches (1 17 cm) Length 108 inches (274 cm) Designed W idth (i[...]

119 SPECIFICA T IONS 800 RUSH Clutching Chart AL TI TUDE Meters (Feet) Drive Cl utch Shift W eight Drive Clutch Spri ng D riven Clutch Spr i ng Driven Helix Chaincase Gearing/ Pitch *Shaded cells indicate factory settings. N.A. INTL 0-600 (0-2000) 10-66 (1321584) 120/310 Black (7043681) LH BLUE/BLA CK T eam (7043064) (64/42/.36) LW ER (5135401) 22:[...]

120 TROUBLESHOOTING Engine T roubleshooting Unless you have experience and training in two-cycle engine repair , see your dealer if technical problems arise. Problem Probable Ca use Solution Erratic engine oper- ating RPM during acceleration o r load variations Drive clutch binding • SEE YOUR DEALER. Driven clutch mal- function • SEE YOUR DEALE[...]

121 TROUBLESHOOTING Engine T roubleshooting Problem Probable Ca use Solution Noise in drive system Broken drive clutch components • SEE YOUR DEALER. Bearing failure/ chaincase, jackshaft, or front drive shaft • SEE YOUR DEALER. Drive belt surface flat spots • Inspect and replace as needed. Drive chain loose • Inspect and adjust (or replace)[...]

122 TROUBLESHOOTING Engine T roubleshooting Problem Probable Ca use Solution Engine turns but fails to start Faulty ignition • Install new spark plug(s). If engine still fails to start, check f or spark. If there's no spark, SEE YOUR DEALER. No fuel to engine • Make sure the fuel valve is on. • Make sure the fuel tank contains fuel. • [...]

123 TROUBLESHOOTING Suspension T roubleshooting Problem Solution Rear suspension bottoms too easily • Adjust rear shock spring (see pages 47 and 55). • Change rear shock spring (see your dealer). • Revalve rear track shock (see your dealer). Rides too stiff in rear • Check for binding suspension shafts and grease all pivot points. • Adjus[...]

124 TROUBLESHOOTING Drive Belt T roubleshooting Belt W ear/Burn Diagnosis Causes Solutions Driving at low RPM • Drive at higher RPMs. Gear the machine down. Check belt deflection. Insufficient warm-up • W arm the engine at least five minutes. T ake the drive belt off the snowmobile in extremely cold weather and warm it up. Break snowmobile loos[...]

125 W ARRANTY Service and W arranty Information Obt aining Service and W arranty Assistance Read and understand the service data and the POLARIS warranty information contained in this manual. Contact your POLARIS dealer for replacement parts, service or war- ranty . Y our dealer receives frequent updates on changes, modifications and tips on snowmo[...]

126 W ARRANTY Limited W arranty POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIMITED W ARRANTY on all components of the POLARIS snowmobile against defects in material or workmanship. W arranty period will vary regionally . This warranty covers the parts and labor char ges for repair or replacement of defective parts th[...]

127 W ARRANTY Limit ations of warranties and re medies ALL IMPLIED W ARRANTIES (INCLUDING BUT NOT LIMITED TO THE IMPLIED W ARRANTIES O F MERCHANT ABILITY AND FITNESS FOR A P AR- TICULAR PURPOSE) ARE LIMITED IN DURA TION TO THE ABOVE ONE YEAR W ARRANTY PERIOD. POLARIS F UR THER DISCLAIMS ALL EXPRESS W AR- RANTIES NOT ST A TED IN THIS W ARRANTY . Som[...]

128 W ARRANTY Conditions and Exclusions In order to qualify for warranty , the product must have been properly set up and tested by a POLARIS Dealer (if applic able). Failure of any dealer to perform the required vehi- cle Pre-Delivery Inspection, perform all ap plicable service bulletins and have the con- sumer sign the PDI form prior to delivery [...]

129 W ARRANTY Exported V ehicles EXCEPT WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W AR- RANTY OR SER VICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER'S AUTHORIZED LOCA- TION. This policy does not apply to vehicles that have received authorization for export from POLARIS Industries. Dealer[...]

130 W ARRANTY Exported V ehicles How to Get Service If Y ou Move : If you move to another country , be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move. V e hicles importa- tion rules vary considerably from country to country . Y ou may be required to present documentation of your mov[...]

131 W ARRANTY U.S.A. EP A Emissions Limited Warranty This emissions limi ted warranty is in additi on to the POLARIS standard limited war - ranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first pur- chased, this emissions-certi fied vehicle is designed, built and equi pped so it conforms with applicable U.S. Environm[...]

132 W ARRANTY U.S.A. EP A Emissions Limited Warranty The exclusive remedy for breach of this limited warrant y shall be, at the exclusive option of POLARIS, repair or replacement of any defective materials, components or products. THE REMEDIES SET FOR TH IN THIS LIMITED W ARRANTY ARE THE ONL Y REMED IES A V AILABLE TO ANY PERSON FOR BREACH OF THIS [...]

133 MAINTENANCE LOG Present this section of your manual to your dealer each time your snow- mobile is serviced. This will provide you and future owners wit h an accurate log of maintenance and se rvices performed on the snowmobile. DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi.[...]

134 MAINTENANCE LOG DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

135 MAINTENANCE LOG DA TE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS[...]

136 INDEX A Accessories . . . . . . . . . . . . . . . . . . . . 57 Air Polluti on . . . . . . . . . . . . . . . . . . . . 6 Avalanches . . . . . . . . . . . . . . . . . . . . . 15 B Belt Break-In . . . . . . . . . . . . . . . . . . . 69 Brake Lever Travel Inspection . . . . . 63 Brakelight Replacement. . . . . . . . . . . 99 Brakes . . . . . . . . [...]

137 INDEX F Front Suspension Inspection . . . . . . . 109 Fuel . . . . . . . . . . . . . . . . . . . . . . . . . . . 71 Fuel Filter . . . . . . . . . . . . . . . . . . . . . . 87 Fuel Lines . . . . . . . . . . . . . . . . . . . . . . 87 Fuel Premi x (In iti al Fill) . . . . . . . . . . . 68 Fuel Pump . . . . . . . . . . . . . . . . . . . . . . 87 F[...]

138 INDEX R Rider Capacity . . . . . . . . . . . . . . . . . . 13 Rider Information Center. . . . . . . . 32-45 Riding Apparel. . . . . . . . . . . . . . . . . . 11 Riding Position . . . . . . . . . . . . . . . . . 10 S Safety Labels . . . . . . . . . . . . . . . . . 21-23 Safety Sym bols . . . . . . . . . . . . . . . . . . 8 Security System . . . [...]

For your nearest Polaris dealer , call 1-800-POLARIS or visit www .polaris.com Polaris Sales Inc., 2100 Hwy . 55, Medina, MN 55340 Phone 1-888-704-5290 Part No. 9924260 Rev 01 Printed in USA PMS 419 *9924260 *[...]