Polaris 2015 600 / 800 RUCH manual

Snowmobile Owner's Manual for Maintenance and Safety 2015 600 / 800 RUSH 2015 600 / 800 SWITCHBACK[...]

IMPORT ANT NOTICE TO OWNER Modifications to this snowmobile are not recommended and may result in voided warranty coverage. Please read the warranty section o f this manual carefully . W ARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautio[...]

1 WELCOME Thank you for purchasing a POLA RIS 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 The following are trademarks of POLARIS Industries Inc.: Copyright 2014 POLARIS Industries Inc. All information contained within this publication is based on th e latest product information at the time of p ublication. Due to constant improvements in the design and quality o f production components, some minor discrepancies may result between the[...]

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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 T[...]

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

6 INTRODUCTION Preservation of the Environment POLARIS is committed to supporting an environmental education campaign. W e encourage state and provincial governments across the snowbelt to adopt rigorous safety training programs that encourage protection of our environment, inclu ding wildlife and vegetat ion. Snowmobile clubs and other or gan izat[...]

7 INTRODUCTION V ehicle Identification Numbers Record your snowmobile 's identification numbers and key number in the spaces provided. NOTE: The V ehicle Identification Nu mber (VIN) is stamped into the side of the tunnel and printed on the tunnel VIN label. V ehicle Model Number: _ __________________________________________________ T unn el V[...]

8 INTRODUCTION Engine Serial Number The engine serial number is located on the identification label on the engine recoil cover . Key Identification The ignition keys are etched with an identification number . Remove the spare key and store it in a safe place. Y our key can be duplicated only by mating a POLARIS key blank using the same identificati[...]

9 SAFETY Operator Safety The following signal words and symbol s appear throughout this manual and on your vehicle. Y our safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symb ol ind icates a potential personal injury hazard. DANGER A DANGER indicates a hazardo[...]

10 SAFETY Operator Safety Follow the recommended maintenance program beginning on page 88 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 d[...]

11 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 [...]

12 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 established 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 b[...]

13 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[...]

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

15 SAFETY Operator Safety Driver Awareness Slow down when traveling near po les, 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 d[...]

16 SAFETY Operator Safety A valanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain: • T ake an avalanche clas s • 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 snowmob[...]

17 SAFETY Operator Safety Ice and Snow Build-up W ARNING! Ice and snow build-up ma y in terfere with the steering of you r 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 full left and right [...]

18 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 long downhi[...]

19 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[...]

20 SAFETY Operator Safety Driving Responsibly Every snowmo bile handles dif ferently , and even th e most docile conditions may become dangerous if operators drive improperly . If you're new to snowmobiling, acqu aint yourself with the snowmobile and with what it will and won't do under various conditions. Even seasoned drivers should spe[...]

21 SAFETY Operator Safety Windchill/T emperature Chart s The following information is provided to help you determine when temperatures 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 ( °[...]

22 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 labe ls depicted in this manual differ from the labels on your snowmobile, always read and follow the instructions of the labels o[...]

23 SAFETY Safety Labels and Locations No Passenger W arning W ARNING This vehi cle is de signed for operator only . NO P ASSENGER. 718101 2 Fuel Recommendation Label 91+ Octane without Ethanol. For maximum performance see decal on lef t hand side p anel for setting. 7181061 Reverse W a rning W ARNING Reverse operation, even at low speeds, can cause[...]

24 SAFETY Safety Labels and Locations Operation W arning W ARNING • T o a void seriou s injury o r death, read and understand all warn in gs and the Owner's Manual before operation. If man ual is missing, contact a POLARIS dealer for a replacement. • This vehicle is cap able of high speeds. Buried objec t s or uneven terrain can cause loss[...]

25 SAFETY Safety Labels and Locations Clutch W arning/Belt Removal W ARNING Do not operate engine with hood o r side p anels open. Do not attempt adjustment with engine ru nning. Do not operate engine with the clutch guard removed. Never run en gin e with drive belt removed. Never service clutches yourself - See your dealer . Belt Removal - All Uni[...]

26 FEA TURES 8 13 5 7 12 11 2 1 4 1. Nosepan 2. Skis 3. Front Bumper 4. Hood 5. Headlight 6. Windshield (accessory) 7. Handlebar 8. Operator Seat 9. T aillight 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 (Inside engine compartmen t) 17. L-Wrench 15 14 3 6 9 10 16 17[...]

27 FEA TURES 1. Brake Lever 2. Instr ument Cluster (Interactive Digital Display shown) 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. POLARIS Elect ronic Reverse (PERC) Button 1 1. Mode/Set Switch 12. Headlight Dimmer Switch 3[...]

28 FEA TURES Adjust able Headlight The headlight can be adjusted for vertical aim using the following procedure. 1. In a well-ventilated area, position the snowmobile on a level surface with the headlight approximately 25 feet (7.6 m) from a wall. 2. Place the rider or the approximate weight of the rider on the seat or tunnel floorboards. 3. Measur[...]

29 FEA TURES Heated Storage Comp artment The storage compartment on the top of the console is heated by engine compartment heat. This compartment can be used to warm gloves or defog goggles. 12-V olt Receptacle If equipped, the 12-volt DC receptacle is located on the console next to the instrument cluster . If not equipped, the receptacle can be in[...]

30 FEA TURES Saddlebags Some snowmobiles are equipped with saddlebags. LOCK & RIDE saddlebags can be added as an accessory on other models. Please see your POLARIS dealer for more information. Three (3) locking plungers secure each saddlebag to the rear car go rack. T o remove a saddlebag, open each plunger latch, then pull the bag away from th[...]

31 FEA TURES Fuel T ype Selection Whenever using ethanol, MTBE or other forms of oxygenated gasoline, the fuel type designation setting must be changed to “Eth” 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 safegu[...]

32 FEA TURES Detonation Elimination T echnology (DET) The DET system prevents damage to the engine from detonation by entering an engine protection mode whenever the DET system is active. When excessive detonation is detected, the check engine light will illuminate. Y ou may notice decreased engine performance and RPM when the DET system is activat[...]

33 FEA TURES Detonation Elimination T echnology (DET) The most likely causes of severe detonation are outlined in the troubleshooting table below . DET T roubleshooting Cause of DET Activation Solution Poor quality fuel Replace with higher quality fuel Incorrect ethanol/non-ethano l fuel type setting V erify correct fuel type setting on gauge Low f[...]

34 FEA TURES Engine Overheat Indicators Over-T emperature Indicator (S tand ard Cluster) The over -temperature indicator on the standard instrument cluster will illuminate when the engine is overheating. T ake action to cool the engin e. See page 35. The indicator will flash when engine temperature reaches critical levels. St o p t h e engine immed[...]

35 FEA TURES Engine Overheat Indicators Engine-Cooling Actions If the engine is overheating, promptly take action to cool the engine. • Drive in loose snow . • V iew the coolant level. Do not open the pr essur e cap while the engine is hot . Add coolant if the level is low . • Stop the engine and allow it to cool down. NOTICE: If you must con[...]

36 FEA TURES S t andard Instrument Cluster The instrument cluster contains indicator lights and the rider information center . The information center 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[...]

37 FEA TURES S t andard 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 92 for diagnostic code definitions. Over-T emperature Indicator This indicator illuminates to alert [...]

38 FEA TURES S t andard 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 temperature and diagnostic display mode. Setting changes must be made with[...]

39 FEA TURES S t andard 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 40. 2. Speed Display - The speed display area displays either v[...]

40 FEA TURES S t andard 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 ma[...]

41 FEA TURES S t andard 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 vehicle on a trip if t[...]

42 FEA TURES S t andard 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 bu[...]

43 FEA TURES S t andard 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 una[...]

44 FEA TURES S t andard 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 order 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[...]

45 FEA TURES S t andard 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 i s running, the display w ill alternate between SECURE ON and ENTER CODE. Wait until ENTER CODE displays, then press and release SEL to advance the digit.[...]

46 FEA TURES S t andard Instrument Cluster Rider Information Center Security System (Ignition Lock Syste m) Locking the System Wit h Y our Personal Security Code 1. Star t 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[...]

47 FEA TURES S t andard Instrument Cluster Rider Information Center Security System (Ignition Lock Syste m) Unlocking the System With Y our Personal Secur i ty 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 f[...]

48 FEA TURES S t andard 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 T ime Use of Y our Security System procedure beginning on page 44. Instead of using the factor[...]

49 FEA TURES S t andard 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 sto[...]

50 FEA TURES Interactive Digit al Display (IDD) The Interactive Digital Display (IDD) provides the rider with: The IDD also offers GPS mapping and Bluetooth ® connectivity for compatible smartphones/devices. This feature will display text messages and missed phone calls on the display screen. The IDD sub-menus and most display features are control[...]

51 THE PERFECT FIT Suspension Quick Set-Up Guide Introduction The front suspension and PRO-XC rear suspension on your AXYS snowmobile is incredibly easy to adjust. Just remember three simple steps: 1. Ride your snowmobile! 2. Adjust the r ear trac k shock spring to tune vehicle balance (ski pressure and weight transfer). 3. Adjust shock clickers to[...]

52 THE PERFECT FIT Suspension Quick Set-Up Guide Ride Experience T able Shock Locations Ride Experience Adjustment To o “ L I T E ” •Ski pressure is too light •Skis push Increase rear track shock spring preload OR Decrease front track shock spring preload To o m u c h “ B I T E ” •Ski pressure is too heavy •S teering is heavy Decrea[...]

53 THE PERFECT FIT Suspension Quick Set-Up Guide Front Suspension (IFS) Factory Spring Settings CAUTION! Never exceed the minimum/maxi mum spring preload settings. Always remove the vehicle weight from the spring prior to making adjustments. Front Suspension (IFS) Factory Clicker Settings Spring Setting Model Spring Rate Preload (Factory Setting) P[...]

54 THE PERFECT FIT Suspension Quick Set-Up Guide Front (IFS) Shock Adjustment s SOFTER TA L L E R STIFFER LOWER M E A S U R E H E R E[...]

55 THE PERFECT FIT Suspension Quick Set-Up Guide Front T rack Sho ck Factory Spring Settings CAUTION! Never exceed the minimum/maxi mum spring preload settings. Always remove the vehicle weight from the spring prior to making adjustments. Front T rack Sho ck Factory Clicker Settings Spring Setting Model Spring Rate Preload (Factory Setting) Preload[...]

56 THE PERFECT FIT Suspension Quick Set-Up Guide Front T rack Sho ck Adjustment s SOFTER MEASURE HERE STIFFER MORE LITE MORE BITE[...]

57 THE PERFECT FIT Suspension Quick Set-Up Guide Rear T rack Shock Factory Spring Settings CAUTION! Never exceed the minimum/maxi mum spring preload settings. Always remove the vehicle weight from the spring prior to making adjustments. Rear T rack Shock Factory Clicker Settings Spring Setting Model Spring Rate Preload (Factory Setting) Preload (Mi[...]

58 THE PERFECT FIT Suspension Quick Setup Guide Rear T rack Shock Ad justments SOFTER M E A S U R E H E R E STIFFER MORE LITE MORE BITE[...]

59 THE PERFECT FIT Suspension Quick Setup Guide Limiter Strap Adjustment The front torque arm limiter strap is set at position #1. POLARIS recommends leaving the limiter strap length at position #1 to maintain the optimum ride characteristics of the snowmobile. Riders who desire less ski pressure and more weight transfer toward the rear of the snow[...]

60 THE PERFECT FIT Handlebar Adjustment s Riser Angle Riser angle can be adjusted to suit rider preference. Factory settings are shown belo w . 1. Loosen the four bolts on the bottom of the adjust er block. If necessary , pry the blocks apart with a screwdriver . 2. Adjust the riser forward or rearward to the desired position. 3. T ighten the bolts[...]

61 THE PERFECT FIT Handlebar Adjustment s Handlebar Angle Handlebar angle can be adjusted to suit rider preference. Factory settings are shown below . 1. Loosen the four bolts on the top riser block. 2. Adjust the handlebar upward or do wnward to the desired angle. Be sure the handlebar , brake lever and throttle lever operate smoothly and do not h[...]

62 THE PERFECT FIT Handlebar Component Fastener T orques Component T orque Do not over-tight en 1. Left Handlebar Control Block 20 in-lbs (2.3 Nm) 2. Brake Lever / Master Cylinder 70 in-lbs (7.9 Nm) 3. Hand Gua rd Mounts (if applicable) Hand-T ight 4. Upper / Lower Riser Clamps 14.8 ft-lbs (20 Nm) 5. Auxiliary Engine Stop Switch Set Screw 12 in-lbs[...]

63 THE PERFECT FIT Handlebar Component Locations Refer to the following illustration and measurements to position handlebar components at factory-specified locations. Handlebar Component Alignment Me asurement s 1. .01 1 in. (3 mm) 2. 6.65 in. (169 mm) 3. 6.7 in. (170 mm) 4. 10 in. (254 mm) 5. .47 in. (12 mm) 6. .08 in. (2 mm)[...]

64 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[...]

65 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 steering and control. See page 125. Maintain a proper ba[...]

66 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 referenced pages. Item See Page Drive Belt Condi tion 1 15 S teering System 71 Recoil Rope 71 Coolant Level 105 Chaincase Oil Level 98 Injection Oil Level 80 Parking Brake [...]

67 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 following items on a weekly basis or before any long trip. Item See Page Check suspensi[...]

68 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 malfunctioni ng components could result in serio[...]

69 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 NOTICE: Do not pump the brake lever when performing this procedure. Squeeze the brake lever . It should move no closer to the handgrip than 1/2 inch (1.3 cm). A smaller distance indicates l[...]

70 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. Fluid Level Indicator 3. Master Cylinder Reservoir/Cover 4. Parking Brake Lever Lock Lock[...]

71 PRE-RIDE INSPECTIONS Before St arting the Engine Steering System W ARNING! Ice and snow build-up ma y in terfere with the steering of you r 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 [...]

72 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[...]

73 OPERA TION Ignition Switch The ignition switch has three positions. If equipped with electric start, turn the key to ST AR T to crank the engine. When the key is released, it automatically returns to the RUN position. Snowmobiles equipped with electric start and/or IDD are equipped with a battery . If the key remains in the RUN position after us[...]

74 OPERA TION S t arting the Engine NOTICE: Engaging the starter when the engine is running 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 urn the key to the RUN position. 2. Pull the auxiliary engine stop switch up to the RUN position. 3. If equipped with[...]

75 OPERA TION 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 necessary[...]

76 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 speeds to reduce friction on all close- fitting machi[...]

77 OPERA TION 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 snowmobile and the moving track. Never hold the snowmobile up or stand behind it while warming up the track. Do not use excessive throttle during warm-up or when the track is free-hanging. Use a stable rear su[...]

78 OPERA TION Fuel Gasoline is h ighly flammable and explosive under certain conditions. • Always exercise extreme caution w henever handling gasoli ne. • Always refuel outdoors or in a well-ventilated area. • Always turn off the engine before refuelin g. • Do not overfill the tank. Do not fill the tank neck. • Do not smoke or allow open [...]

79 OPERA TION 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 . NOT[...]

80 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. S ee page 75 for oil recommendations. 1. Immediately stop the engine if the low oil indicator light comes on. 2. Open the left side panel. See page 94. 3. V iew the oil level in the oil bottle. 4. Add oil as nee[...]

81 OPERA TION Auxiliary Engine St op Switch Push the auxiliary engine stop switch down to ground out the ignition and stop the engine quickly . Pull the switch up to the RUN position to allow restarting. Throttle Release Switch The throttle release switch is designed to stop the engine if all pressure is removed from the throttle lever and the thro[...]

82 OPERA TION Throttle Lever W ARNING! An improperly functionin g thro ttle lever may cause erratic snowmobile behavior a nd loss of control, wh ich could result i n serious injury or death. If the thro ttle lever does not work properly , DO NOT start the engine. If the engine stops abruptly when the throttle lever is released: 1. T urn the ignitio[...]

83 OPERA TION Throttle Lever Throttle Lever Freeplay Adjustment Adjust throttle lever freeplay using the in-line throttle cable adjuster . 1. Locate the in-line adjuster on the throttle cable. 2. Loosen the lock nut. 3. Rotate the adjuster clockwise to DECREASE freeplay . Rotate the adjuster counter-clockwise to INCREASE freeplay . 4. When freeplay[...]

84 OPERA TION POLARIS Electronic Reverse Control (PERC) Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Dama ge will occur to the chaincase 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 whe[...]

85 OPERA TION POLARIS Electronic Reverse (PERC) Engaging Reverse 1. Stop 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 second, then releas e. The engine will automatical ly reduce RPM and start a reverse rotation. A flashing reverse[...]

86 OPERA TION Daily St orage At the end of each ride, park the snowmobile on a level surface and support 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&apos[...]

87 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 control information (ECI) label and a factory-installed emissions information [...]

88 MAINTENANCE POLARIS Recommended Maintenance Program T o ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as outlined in this manual. Record maintenance and service in the Maintenance Log beginning on page 171. The recommended maintenance sche dule on your snowmobile calls[...]

89 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 replac ement parts, always use genuine POLARIS parts, available from your POLARIS dealer . I - Inspect (clean, adjust, tighten, lu[...]

90 MAINTENANCE Periodic Maintenance Interval T able I - Inspect (clean, adjust, tighten, lubricate, replace if necessar y) C - Clean R - Replace L - Lubricate 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 Pad[...]

91 MAINTENANCE Periodic Maintenance Interval T able I - Inspect (clean, adjust, tighten, lubricate, replace if necessary) C - Clean R - Replace L - Lubricate Item See Page Frequency 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi. (3200 km) Pre- Season CHASSIS Ski T oe Alignment -- II I Suspension Mounting Bolts -- II I I I Bolt T orqu[...]

92 MAINTENANCE 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. Shorted Load: The wires leading to the item [...]

93 MAINTENANCE Diagnostic Display Code Definitions Diagnostic Codes Component Condition SPN FMI Knock Level Cylinder 1 (MAG) Maximum Detonation Correction Limit Reached 1352 0 Knock Above Critical Level 16 Knock Level Cylinder 2 (PTO) Maximum Detonation Correction Limit Reached 1353 0 Knock Above Critical Level 16 Sensor Supply V oltage 1 (TPS/TMAP[...]

94 MAINTENANCE Hood and Side Panels The hood and side panels protect the operator from moving parts. Never operate a snowmobile with the side panels open or removed. Always ensure that the hood and side panels are installed and securely latched before starting the engine. Side Panels (Opening/Removing) T o open a side panel, rotate the two 1/4-turn[...]

95 MAINTENANCE Hood Removal and Inst allation 1. Remove the side panels. 2. Rotate the 1/4-turn fasteners at the upper corners of the hood. 3. Disconnect the wire harness leading to the console electronics. 4. Remove the hood assembly . 5. T o reinstall the hood, slide the nose clips into the nosepan. 6. Position the hood and align the 1/4-turn fas[...]

96 MAINTENANCE To o l s An L-wrench and a tool kit (containing a spare belt, spark plug wrench and provisions for two spare spark plugs) are provided with the snowmobile. Open the left side panel to access the tools. The L-wrench is used to open and close the driven clutch when working with the drive belt. The L-wren ch, when properly engaged in th[...]

97 MAINTENANCE To o l s 4. Pull the container out of the compartment. 5. When reinstalling the drive belt into the container , fold the belt as shown. V erify that the belt loop at the rear of the container is positioned slightly higher than the front loop. 6. Slide the container into the engine compartment at an angle. 7. Position the container br[...]

98 MAINTENANCE Rear Shock Body Lubricate rear shock body threads seasonally with a low-temperature synthetic grease. Driveshaf t Bearing This model has sealed bearings that require no additional lubrication. Chaincase Oil Check and change the chaincase oil at the intervals outlined in the Periodic Maintenance T able beginning on page 88. Maintain t[...]

99 MAINTENANCE Chaincase Oil Oil Change (Pump Method) NOTE: This procedure requires the use of a commercially available hand pump oil extractor . 1. Elevate the front of the snowmobile using a floor jack or appropriate lift. 2. Remove the fill plug. Clean all metal shavings of f the plug. 3. Insert the tube of a hand pump oil extractor into the fil[...]

100 MAINTENANCE Chaincase Oil Oil Change (Cover Drain Method) 1. Position the snowmobile on a level surface. 2. Remove the two screws securing the fender to the chaincase. 3. Remove the right side panel. If equipped with a battery , remove the battery and bracket. NOTICE: When removing the battery , disconnect the BLACK (-) cable first, and then di[...]

101 MAINTENANCE Chaincase Oil Oil Change (Cover Drain Method) 10. Using a funnel, slowly add the recommended oil until the fluid begins to overflow . Maximum fl uid capacity is 10.5 oz. (310 ml). 1 1. Clean the area with a clean, dry shop towel. 12. Reinstall the fill plug. To r q u e : 6-10 ft-lbs (8-13 Nm) 13. Reinstall the screws securing the fe[...]

102 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 . Foam Filt er s[...]

103 MAINTENANCE Spar k P l u g s Sp ark Plug Recommendations A new engine can cause temporary spark plug fouling due to the preservative added during the assembly process. A void prolonged idle speeds, which cause plug fouling and carbonization. Change the spark plugs at the intervals outlined in the Periodic Maintenance T able beginning on page 88[...]

104 MAINTENANCE Spar k P l u g s Sp ark Plug Inspection 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[...]

105 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 operated at extremely low temperatures, greater protection may be required. Please see your POLARIS[...]

106 MAINTENANCE Cooling System Flushing the Cooling System T o ensure that the coolant maintains its ability to protect the engine, drain the system completely every five (5) years and add a fresh mixture of antifreeze and distilled water . This service must be performed when the engine is cold. Ask your POLARI S dealer to check the coolant when he[...]

107 MAINTENANCE Cooling System Bleeding the Cooling System 6. Fill the coolant bottle to the COLD FILL mark. 7. Install the coolant bottle cap to the first lock. Do not tighten to the fully seated position. 8. Lock the parking brake. 9. Star t the engine and allow it to run at a fast idle for several minutes, until the heaters are warm to the touch[...]

108 MAINTENANCE Exhaust System Check the exhaust system for wear or damage at approximately 2,000 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 runni[...]

109 MAINTENANCE Drive Chain T ension Check drive chain tensio n at the intervals outlined in the Periodi c Maintenance T able beginning on page 88. Che ck again before each long trip. 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. 1. Remov[...]

110 MAINTENANCE Brakes Hydraulic Brake Inspection Inspect brake lever travel before eac h use of the snowmobile. See page 69. Brake pads must be replaced when the brake pad material becomes thinner than the backing plate (approximately 1/16 inch or 1.5 mm). A kit is available for replacing brake pads. Please see your dealer . W ARNING! Brake failur[...]

111 MAINTENANCE Brakes Brake Fluid Replace brake fluid at least every two years with POLARIS DOT 4 high temperature brake fluid. See page 137 for the part numbers of POLARIS products. W ARNING! After opening a bottle of brake fluid, always discard an y unused portion. Never store or use a partial bottle. Brake fluid is hyg roscopic, meaning it rapi[...]

112 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 wi th a spongy brake lever can result in loss of brakes, which could cause an accident and lead to serious injury or death. Never operate[...]

113 MAINTENANCE Light s The headlight and taillight assemblies feature LED elements and are not serviceable. If an LED fails to illuminate in either the headlight or taillight, the entire assembly must be replaced. Please see your POLARIS dealer . Headlight T aillight[...]

114 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 unu sual vibration or shift pattern, see your dealer immediately . Do not opera[...]

115 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 T roubleshooting on page 162. Always carry a spare drive belt. [...]

116 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 Deflection Adjustment 1. Loosen the 1 1 mm jam nut on th[...]

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

118 MAINTENANCE Clutch System Drive Belt Inst allation 1. V erify the driven clutch sheaves are open. If they are not, install the L-wrench and open the sheaves. NOTE: When installing the be lt, verify POLARIS or the part number can be read from the outside of the snowmobile. 2. Drop the drive belt over the drive clutch and pull back the slack. The[...]

119 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[...]

120 MAINTENANCE T rack Maintenance W ARNING! Moving parts can cut and crush body p arts. 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[...]

121 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 120. If the track needs adjustment: 6. Loosen the rear idler shaft bolt. 7. Loosen the locknuts. 8. T ighten or loosen the track ad justing screws to provi[...]

122 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 the rear of the snowmobile with the track of f the ground. 2. Star t the engine and apply a small amount of throttle unt il the[...]

123 MAINTENANCE S teering System Front Suspension Inspection W ARNING! Improper fastener torq ue or front suspension component damage may cause loss of steering contro l, resulting in serious inju ry or death. See your POLARIS dealer . Each week, or before a long ride, check the following items. If component damage or loose fasteners are found, see[...]

124 MAINTENANCE S teering System Ski Alignment W ARNING! Improper ski alignment o r adjustment may cau se loss of steering control, resulting in se rious injury or d eath. Do not attempt to change the ski alignment or toe adjustment. See your POLARIS dealer . If the steering feels heavy , or if the snowmobile seems to pull or dart to the side, ski [...]

125 MAINTENANCE S teering System Ski Skags W ARNING! Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causi ng seri ous injury or death. See your dealer's studding chart fo r recommended skags. If you install lon ger or more aggressive carbide skags than the original equipment, it may also be necessary[...]

126 MAINTENANCE Front Suspension Control Arms Control Arm Pivot Adjustment The upper and lower control arms feature slotted pivots to allow for adjustment to compensate for bushing wear . NOTE: Upper control arm shown. Procedure is the same for lower control arm adjustment. 1. Loosen the four lock nuts. 2. From the bushing side of each pivot, push [...]

127 MAINTENANCE Rear Suspension Rear Suspension Inspection W ARNING! Improper fastener torq ue or rear suspen sion component damage may cause loss of vehicle control, resulting in serious injury or death. See your POLARIS dealer . Each week, or before a long ride, check the following items. If component damage or loose fasteners are found, see your[...]

128 MAINTENANCE Rear Suspension 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). 7/16 inch (1.1 cm) X[...]

129 MAINTENANCE Battery (if equipped) W ARNING! Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death . Wh en removin g the battery , always disconnect the negative (black) ca ble first. When reinstalling the battery , always connect the negative (black) cable last. Battery Removal CAUTIO[...]

130 MAINTENANCE Battery (if equipped) Battery Removal 7. Remove the screw (4) securing the battery shield to the chassis. 8. Remove the battery shield (5). 9. Pull the fender away from the battery compartment and remove the battery . 10. With the battery removed from the snowmobile, the battery bracket can be removed to access the chaincase. Remove[...]

131 MAINTENANCE Battery (if equipped) Battery Inst allatio n When installing a new battery , make sure it’ s fully charged prior to its initial use. Using a new battery that has not been fully char ged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery char ging instructions on page 132[...]

132 MAINTENANCE Battery (if equipped) Battery Charging The following battery char ging instructions apply only to the installation of a sealed battery . Read all instructions before proceeding with the installation of this battery . The sealed battery is already filled w ith electrolyte and has been sealed and fully char ged at the factory . Do not[...]

133 MAINTENANCE Battery (if equipped) Battery Charging For a refresh charge, follow all instructions carefully . 1. Check the battery voltage with a voltmeter or multimeter . A fully charged battery will register 12.8 V or higher . 2. If the voltage is less than 12.8 volts, recharge the battery at 1.2 amps or less until the battery voltage is 12.8 [...]

134 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 ot her contaminants. POLARIS Ind[...]

135 MAINTENANCE Cleaning and Preservation Proper storage starts with cleaning, wa shing, and waxing the hood, side panels, chassis, and plastic parts. W ipe down remaining surfaces with a damp cloth. Clean and touch up with paint any rusted or previously painted surfaces. Be sure that corrosive salt and acids are removed from surfaces before beginn[...]

136 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 prevention of rust a[...]

137 POLARIS PRODUCTS Part No. Description Engine L ubricant s 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) [...]

138 SPECIFICA TIONS 600 RUSH PRO-S Cap acities and Dimensions Body Style AXYS Rider Capacity 1 Coolant Capacity 4 qts. (3.8 l) Chaincase Oil Capacity Fill to Spill / 8 - 10 oz. (237 - 296 ml) Dependent on sprocket / chain size Fuel T ank Capacity 12 gal. (45.4 l) Height 46 inches (1 17 cm) Length 1 14 inches (289.6 cm) Estimated Dry W eight 432 lbs[...]

139 SPECIFICA TIONS 600 RUSH PRO-S 600 RUSH PRO-S T raction / Control Clutching Chart AL TITUDE Meters (Feet) Drive Cl utch Shift W eight 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 140/330 7043829 Black/Purple 7043363 48/42-.36 5139626 22:4[...]

140 SPECIFICA TIONS 600 RUSH PRO-X (International) Cap acities and Dimensions Body Style AXYS Rider Capacity 1 Coolant Capacity 4 qts. (3.8 l) Chaincase Oil Capacity Fill to Spill / 8 - 10 oz. (237 - 296 ml) Dependent on sprocket / chain size Fuel T ank Capacity 12 gal. (45.4 l) Height 46 inches (1 17 cm) Length 1 14 inches (289.6 cm) Estimated Dry[...]

141 SPECIFICA TIONS 600 RUSH PRO-X (International) 600 RUSH PRO-X (International) T raction / Control Clutching Chart AL TITUDE Meters (Feet) Drive Cl utch Shift W eight 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 140/330 7043829 Black/Purpl[...]

142 SPECIFICA TIONS 600 SWITCHBACK PRO-S Cap acities and Dimensions Body Style AXYS Rider Capacity 1 Coolant Capacity 4 qts. (3.8 l) Chaincase Oil Capacity Fill to Spill / 8 - 10 oz. (237 - 296 ml) Dependent on sprocket / chain size Fuel T ank Capacity 12 gal. (45.4 l) Height 46 inches (1 16.8 cm) Length 121 inches (307.4 cm) Estimated Dry W eight [...]

143 SPECIFICA TIONS 600 SWITCHBACK PRO-S 600 SWITCHBACK PRO-S Clutching Chart AL TITUDE Meters (Feet) Drive Cl utch Shift W eight 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 140/330 7043829 Black/Purple 7043363 48/42-.36 5139626 22:41-70 600[...]

144 SPECIFICA TIONS 600 SWITCHBACK PRO-X (International) Cap acities and Dimensions Body Style AXYS Rider Capacity 1 Coolant Capacity 4 qts. (3.8 l) Chaincase Oil Capacity Fill to Spill / 8 - 10 oz. (237 - 296 ml) Dependent on sprocket / chain size Fuel T ank Capacity 12 gal. (45.4 l) Height 46 inches (1 16.8 cm) Length 121 inches (307.4 cm) Estima[...]

145 SPECIFICA TIONS 600 SWITCHBACK PRO-X (International) 600 SWITCHBACK PRO-X (International) Clutching Chart AL TITUDE Meters (Feet) Drive Cl utch Shift W eight 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 140/330 7043829 Black/Purple 704336[...]

146 SPECIFICA TIONS 600 SWITCHBACK ADVENTURE Cap acities and Dimensions Body Style AXYS Rider Capacity 1 Coolant Capacity 4 qts. (3.8 l) Chaincase Oil Capacity Fill to Spill / 8 - 10 oz. (237 - 296 ml) Dependent on sprocket / chain size Fuel T ank Capacity 12 gal. (45.4 l) Height 49 inches (124.5 cm) Length 121 inches (307.4 cm) Estimated Dry W eig[...]

147 SPECIFICA TIONS 600 SWITCHBACK ADVENTURE 600 SWITCHBACK ADVENTURE Clutching Chart AL TITUDE Meters (Feet) Drive Cl utch Shift W eight 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 140/330 7043829 Black/Purple 7043363 48/42-.36 5139626 22:4[...]

148 SPECIFICA TIONS 600 SWITCHBACK ADVENTURE (International) Cap acities and Dimensions Body Style AXYS Rider Capacity 1 Coolant Capacity 4 qts. (3.8 l) Chaincase Oil Capacity Fill to Spill / 8 - 10 oz. (237 - 296 ml) Dependent on sprocket / chain size Fuel T ank Capacity 12 gal. (45.4 l) Height 49 inches (124.5 cm) Length 121 inches (307.4 cm) Est[...]

149 SPECIFICA TIONS 600 SWITCHBACK ADVENTURE (International) 600 SWITCHBACK ADVENTURE (International) Clutching Chart AL TITUDE Meters (Feet) Drive Cl utch Shift W eight 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 140/330 7043829 Black/Purpl[...]

150 SPECIFICA TIONS 800 RUSH PRO-S Cap acities and Dimensions Body Style AXYS Rider Capacity 1 Coolant Capacity 4 qts. (3.8 l) Chaincase Oil Capacity Fill to Spill / 8 - 10 oz. (237 - 296 ml) Dependent on sprocket / chain size Fuel T ank Capacity 12 gal. (45.4 l) Height 46 inches (1 17 cm) Length 1 14 inches (289.6 cm) Estimated Dry W eight 431 lbs[...]

151 SPECIFICA TIONS 800 RUSH PRO-S 800 RUSH PRO-S Clutching Chart AL TITUDE Meters (Feet) Drive Cl utch Shift W eight Drive Clutch Spri ng Driven Clu tch Spr i ng Driven Helix Chaincase Gearing/ Pitch *Shaded cells indicate factory settings. 0-600 (0-2000) 10-66 1321584 Gold 7041 148 Blue / Black 7043064 58/44-.36 23-37-68 600-1200 (2000-4000) 10-6[...]

152 SPECIFICA TIONS 800 RUSH PRO-X Cap acities and Dimensions Body Style AXYS Rider Capacity 1 Coolant Capacity 4 qts. (3.8 l) Chaincase Oil Capacity Fill to Spill / 8 - 10 oz. (237 - 296 ml) Dependent on sprocket / chain size Fuel T ank Capacity 12 gal. (45.4 l) Height 48 inches (121.9 cm) Length 1 14 inches (289.6 cm) Estimated Dry W eight 435 lb[...]

153 SPECIFICA TIONS 800 RUSH PRO-X 800 RUSH PRO-X Clutching Chart AL TITUDE Meters (Feet) Drive Cl utch Shift W eight Drive Clutch Spri ng Driven Clu tch Spr i ng Driven Helix Chaincase Gearing/ Pitch *Shaded cells indicate factory settings. 0-600 (0-2000) 10-66 1321584 Gold 7041 148 Blue / Black 7043064 58/44-.36 22-41-70 600-1200 (2000-4000) 10-6[...]

154 SPECIFICA TIONS 800 SWITCHBACK PRO-S Cap acities and Dimensions Body Style AXYS Rider Capacity 1 Coolant Capacity 4 qts. (3.8 l) Chaincase Oil Capacity Fill to Spill / 8 - 10 oz. (237 - 296 ml) Dependent on sprocket / chain size Fuel T ank Capacity 12 gal. (45.4 l) Height 46 inches (1 17 cm) Length 121 inches (307.4 cm) Estimated Dry W eight 44[...]

155 SPECIFICA TIONS 800 SWITCHBACK PRO-S 800 SWITCHBACK PRO-S Clutching Chart AL TITUDE Meters (Feet) Drive Cl utch Shift W eight Drive Clutch Spri ng Driven Clu tch Spr i ng Driven Helix Chaincase Gearing/ Pitch *Shaded cells indicate factory settings. 0-600 (0-2000) 10-66 1321584 Gold 7041 148 Blue / Black 7043064 58/44-.36 23-37-68 600-1200 (200[...]

156 SPECIFICA TIONS 800 SWITCHBACK PRO-X Cap acities and Dimensions Body Style AXYS Rider Capacity 1 Coolant Capacity 4 qts. (3.8 l) Chaincase Oil Capacity Fill to Spill / 8 - 10 oz. (237 - 296 ml) Dependent on sprocket / chain size Fuel T ank Capacity 12 gal. (45.4 l) Height 48 inches (121.9 cm) Length 121 inches (307.4 cm) Estimated Dry W eight 4[...]

157 SPECIFICA TIONS 800 SWITCHBACK PRO-X 800 SWITCHBACK PRO-X Clutching Chart AL TITUDE Meters (Feet) Drive Cl utch Shift W eight Drive Clutch Spri ng Driven Clu tch Spr i ng Driven Helix Chaincase Gearing/ Pitch *Shaded cells indicate factory settings. 0-600 (0-2000) 10-66 1321584 Gold 7041 148 Blue / Black 7043064 58/44-.36 22-41-70 600-1200 (200[...]

158 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 operating RPM during acceleration or load variations Drive clutch binding • SEE YOUR DEALER. Driven clutch malfunction • SEE YOUR DEALER. Ha[...]

159 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)[...]

160 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 tank contains fuel. • Ice may be in the fuel line, filter [...]

161 TROUBLESHOOTING Suspension T roubleshooting Problem Solution Rear suspension bottoms too easily • Adjust rear track shock clicker stiffer (see pages 57 and 58). • V erify rear spring is not broken / dislodged. • Rebuild rear track shock (see your dealer). Rides too stif f in rear • Adjust rear track shock clicker softer ( • Check for [...]

162 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. Parking brake engaged • V erify parking brake is not engaged. Insufficient warm-up • W arm the engine at least five minutes. T ake the drive belt off the snowmobile[...]

163 W ARRANTY Service and W arranty Information Obt aining Service and Warranty Assist ance Read and understand the service data and the POLARIS warranty information contained in this manual. Contact your POLARIS dealer for replacement parts, service or warranty . Y our dealer receives frequent updates on changes, modifications and tips on snowmobi[...]

164 W ARRANTY Limited W arranty POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a 12 MONTH LIMITED W ARRANTY on all components of your POLARIS vehicle against defects in material o r workmansh ip. This warranty covers parts and labor charges for repair or replacement of defective parts and begins on the date of purchase b[...]

165 W ARRANTY W arranty Coverage and Exclusions Limit ations of Warranties and Remedies This POLARIS Limited W arranty excludes any failures that are not caus ed by a defect in material or workmanship. THIS W ARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not co ver acts of God, accidental damage, normal wear and tear , [...]

166 W ARRANTY W arranty Coverage and Exclusions Limit ations of Warranties and Remedies Lubricants and Fluids 1. Mixing oil brands or using non-recomm ended oil may cause engine damage. W e recommend the use of POLARIS engine oil. 2. Damage or failure resulting from the use of non-r ecommended lubricants or fluids is not covered by this warranty . [...]

167 W ARRANTY How to Obt ain W arranty Service If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer . When requesting warranty service you must present your copy of the W arranty Registration Form to the dealer . (THE COST OF TRANSPOR T A TION TO AND FROM THE DEALER IS YOUR RESPONSIBILITY .) POLARIS suggests tha[...]

168 W ARRANTY Exported Product s EXCEPT WHERE SPECIFICALL Y REQUIRED BY LA W , THERE IS NO W ARRANTY OR SER VICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTR Y OF THE SELLING DEALER’S AUTHORIZED LOCA TION. This policy does not apply to products that have received authorization for export from POLARIS. Dealers may not give au[...]

169 W ARRANTY U.S.A. EP A Emissions Limited W arranty This Emissions Limi ted W arranty is in a ddition to the POLARIS standard Limited W arranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehi cle is designed, built and equipped so it conforms with applicable U.S. Environment[...]

170 W ARRANTY U.S.A. EP A Emissions Limited W arranty The exclusive remedy for breach of this Limited W arranty 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 REMEDIES A V AILABLE TO ANY PERSON FOR BREACH OF THIS [...]

171 MAINTENANCE LOG Present this section of your manual to your dealer each time your snowmobile is serviced. This will provide you and future owners with an accurate log of maintenance and services 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. (32[...]

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

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

174 INDEX 0-9 12-Volt Recept ac le . . . . . . . . . . . . . 29 A Adjustabl e Headlights . . . . . . . . . . . 28 Avalanches . . . . . . . . . . . . . . . . . . . . 16 B Battery . . . . . . . . . . . . . . . . . . 129-133 Charging . . . . . . . . . . . . . . . 132-133 Installation . . . . . . . . . . . . . . . . 131 Removal . . . . . . . . . . . . [...]

175 INDEX F Fuel Lines . . . . . . . . . . . . . . . . . . . . 101 Fuel Premi x (In iti al Fill) . . . . . . . . . . 75 Fuel Pump . . . . . . . . . . . . . . . . . . . . 101 Fuel Recomm endation . . . . . . . . . . . 79 Fuel Syste m D ei cers . . . . . . . . . . . . . 79 Fuel Type Selec tion . . . . . . . . . . . . . 31 Fuel Warnings . . . . . . . [...]

176 INDEX S Specifications/Clutching 600 RUSH PRO-S . . . . . . . . . . . . . . 138 600 RUSH PRO-X (I nt’l) . . . . . . . . . 140 600 SWITCHBACK ADV . . . . . . . . 146 600 SWITCHBACK ADV (Int’l) . . . 148 600 SWITCHBACK PRO-S . . . . . . . 142 600 SWITCHBACK PRO-X (Int’l) . 144 800 RUSH PRO-S . . . . . . . . . . . . . . 150 800 RUSH PRO-X . [...]

For your nearest Polaris dealer , call 1-800-POLARIS (765-2747) or visit www .polaris.com Polaris Industries Inc., 2100 Hwy . 55, Medina, MN 55340 Part No. 9925073 Rev 01 Printed in USA *9925073 *[...]