Polaris 600 RUSH Owner's Manual
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Polaris 600 RUSH Owner's Manual

Polaris 600 RUSH Owner's Manual

Polaris 2010 snowmobile owner's manual
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  • Page 1 Pantone 425C...
  • Page 2 Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in serious injury or death. The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.
  • Page 3 The text is printed on 100% recycled with 40% post-consumer waste (PCW).
  • Page 4 Pantone 425C For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 Phone 1-888-704-5290 Part No. 9922276 Rev 02 Printed in USA...
  • Page 5 Polaris enthusiasts. Be sure to visit us online at www.polarisindustries.com for the latest news, new product introduc- tions, upcoming events, career opportunities and more. Here at Polaris we proudly produce an exciting line of utility and recre- ational products. • Snowmobiles •...
  • Page 6 POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Indus- tries Inc. Copyright 2009 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant...

  • Page 7: Table Of Contents

    Polaris Products..... . . 110 Troubleshooting ......111 Warranty .

  • Page 9: Introduction

    INTRODUCTION Important 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.

  • Page 10: Preservation Of The Environment

    Polaris snowmobiles are engineered to conform to these SAE standards. Our muffler systems are designed to reduce noise levels and must not be altered or removed. The sound of your snowmobile may not be welcome to non-snowmobilers, so you have a responsibility to operate your snowmobile with concern for others.

  • Page 11: Vehicle Identification Numbers

    Remove the spare key and store it in a safe place. Your 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.

  • Page 12: Safety

    SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and sym- bols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. WARNING A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.
  • Page 13 Always check major and vital safety components before every ride. All Polaris snowmobiles are designed and tested to provide safe operation when used as directed. Failure of critical machine components may result from opera- tion with any modifications, especially those that increase speed or power. DO NOT MODIFY YOUR MACHINE.

  • Page 14: Riding Position

    SAFETY Operator Safety Stay Clear of Track Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. Do not stand on the plastic flap. WARNING! Serious injuries may result if hands, feet, or clothing become entangled STEP in the track.

  • Page 15: Riding Apparel

    Eye Protection Do not depend on eyeglasses or sunglasses for eye protection. When- ever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE.

  • Page 16: Disabled Operators

    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 Preparation For your safety, always ride in a group of other snowmobilers.

  • Page 17: Rider Capacity

    SAFETY Operator Safety Rider Capacity This snowmobile is designed for a single rider only. Never carry a pas- senger on this snowmobile. Excessive Speed WARNING! 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 local laws governing snowmobile opera- tion and speed limits.

  • Page 18: Driver Awareness

    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.
  • Page 19 Operator Safety Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain: • Take an avalanche class • Travel with experienced people • Travel on designated trails • Make sure each person is equipped with a shovel, probe and avalanche beacon.

  • Page 20: Ice And Snow Build-Up

    SAFETY Operator Safety Ice and Snow Build-up WARNING! Ice and snow build-up may interfere with the steering of your snowmobile, resulting in serious injury or death. Keep the underhood 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 steering.

  • Page 21: Driving Downhill

    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.

  • Page 22: Drive Belt

    SAFETY Operator Safety Drive Belt Do not operate the engine with the drive belt removed. 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.

  • Page 23: Driving Responsibly

    Operator Safety Driving Responsibly Every snowmobile handles differently, and even the most docile condi- tions may become dangerous if operators 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 spend some time getting the feel for a snowmobile before attempting ambitious maneuvers.
  • Page 24 SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when tem- peratures become dangerous for riding. WINDCHILL CHART (_F) Wind Speed Calm Frostbite in >> 30 min. WINDCHILL CHART (_C) Wind Speed Calm -10 -13 -17 -21 -24 -28 -32 -36 -39 -43 -47 -50 -54 -58 -62 -11 -15 -19 -22 -26 -30 -34 -38 -42 -45 -49 -53 -57 -61 -65 -12 -16 -20 -24 -28 -32 -36 -39 -43 -47 -51 -55 -59 -63 -67 -13 -17 -21 -25 -29 -33 -37 -41 -45 -49 -53 -57 -61 -65 -69...

  • Page 25: Clutch Warning

    If any label becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety labels are provided by Polaris at no charge.

  • Page 26: Reverse Warning

    SAFETY Safety Labels and Locations Track Warning The track warning label is at the rear of the snowmobile: WARNING Stay clear of track. Do not sit on seat back. Entanglement with the track or a fall from seat back may result in severe injury or death.

  • Page 27: Operation Warning

    • To avoid serious injury or death, read and understand all warnings and the Owner's Manual before operation. If manual is missing, contact a Polaris dealer for a replacement. • This vehicle is capable of high speeds. Buried objects or uneven ter- rain can cause loss of control.

  • Page 28: Features

    FEATURES 1. Nosepan 2. Skis 3. Front Bumper 4. Hood 5. Headlight 6. Windshield (accessory) 7. Handlebar 8. Operator Seat 9. Taillight 10. Rear Bumper 11. Snow Flap 12. Suspension 13. Track 14. Side Panel 15. Side Panel Fasteners...
  • Page 29 FEATURES 1. Fuel Filler Cap 2. Brake Lever 3. MFD Gauge 4. Ignition Switch 5. Engine Stop Switch 6. Throttle Control 7. Recoil Starter Handle 8. Parking Brake Lock 9. Handlebar Grip Warmer Switch 10. Thumbwarmer Switch 11. Electronic Reverse Button 12.

  • Page 30: Adjustable Headlights

    FEATURES Storage Bag/Tool Kit A storage bag is located under the seat. The left portion of the bag is designed to store the tool kit. The tool kit includes tools and a foam tool holder. The right side of the bag can be used to stow other items. Right Compartment (Storage)

  • Page 31: Detonation Elimination Technology

    Verify correct fuel resistor for fuel type in tank Refuel with recommended fuel Replace with recommended fuel See your Polaris dealer for service Do not add deicers or additives that contain any form of alcohol while using up to 10% ethanol fuel...
  • Page 32 FEATURES Instrument Cluster Check Engine Indicator Over- Temperature Indicator Low Oil Indicator 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.

  • Page 33: Instrument Cluster

    FEATURES 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 36 for diagnostic code definitions. Over-Temperature Indicator This indicator illuminates to alert the operator that the engine is over- heating.

  • Page 34: Rider Information Center

    FEATURES 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 can be made with the engine running or with the engine off.
  • Page 35 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. To change the dis- play, see page 32. 2.

  • Page 36: Information Display Area

    FEATURES Instrument Cluster Rider Information Center Speed Display Area The speed display area displays either vehicle speed or engine speed. Vehicle speed is displayed in either miles per hour (MPH) or kilometers per hour (km/h). Engine speed is displayed in revolutions per minute (RPM).

  • Page 37: Odometer/Engine Hour Display Area

    Instrument Cluster Rider Information Center Odometer/Engine Hour Display Area This area displays the odometer, Trip A meter, Trip 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 is reset before each trip.
  • Page 38 FEATURES Instrument Cluster Rider Information Center Standard/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.

  • Page 39: Diagnostic Display Mode

    Diagnostic Display Mode The diagnostic display mode is for informational purposes 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 diagnostic code is active.

  • Page 40: Diagnostic Display Code Definitions

    FEATURES 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-Ground: The wire is shorted to ground between the electronic control unit and the item listed in the chart.

  • Page 41: Diagnostic Display Code Definitions

    Instrument Cluster Rider Information Center Diagnostic Display Code Definitions Component Ignition Coil Primary Driver 1 (MAG) Fuel Pump Driver Circuit Chassis Relay Exhaust Valve Solenoid ECU Memory Alternator Power Supply Potential (DC-SDI DC Chassis Voltage) (Fuel Pump Power) Sensor Supply Voltage 1 (DC-SDI TPS/TMAP PWR) Sensor Supply Voltage 2 (DC-SDI Ground Speed Sensor PWR)

  • Page 42: The Perfect Fit

    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 spring preload for rider weight. 2. Adjust the rear spring to tune vehicle balance (ski pressure and weight transfer).
  • Page 43 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 for flatter cornering and more precise steering response.
  • Page 44 100 3 7/8 10.1 109 4 1/8 10.5 113 4 1/4 10.8 Spring Guide Accessory 120 Spring See your Polaris dealer to order an accessory spring and the gauge calibrated for that spring. Rider Weight Dimension lbs. 2 5/8 2 3/4...
  • Page 45 Rear Shock Clicker Rear Shock Spring Preload 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 manual.

  • Page 46: Front Suspension Adjustments

    THE PERFECT FIT Front Suspension Adjustments 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 very low weight range for the stock spring, additional adjustments are possible to the IFS.
  • Page 47 Failure to do so could cause the retainer to fall off when the suspension is fully extended. TIP: Other spring options are available. Please see your Polaris dealer.

  • Page 48: Shock Valving

    Shocks contain high-pressure nitrogen gas. Use extreme caution when handling high-pressure service equipment. We recommend that this work be performed by a Polaris dealer. Stiffer Ride...

  • Page 49: Rear Suspension Adjustments

    Rear Suspension Adjustments Rider weight, riding style, trail conditions, and vehicle speed all affect 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 adjustments involve a compromise, or trade-off. For example, a suspension set up for snowcross racing would provide a very stiff ride on the trail.
  • Page 50 Failure to do so could cause the retainer to fall off when the suspension is fully extended. TIP: Other spring options are available. Please see your Polaris dealer. Stiffer Softer...
  • Page 51 Rear Suspension Adjustments Rear Shock Spring Preload Settings Make adjustments to the rear shock spring to tune vehicle balance. Increasing preload will increase ski pressure and result in less weight transfer and flatter cornering and more precise steering response. Decreasing preload will decrease ski pressure and result in more weight transfer, or less weight on the skis when accelerating.

  • Page 52: Handlebar Position

    THE PERFECT FIT Handlebar Adjustments Handlebar Position 1. Loosen the four bolts on the bottom of the adjuster block. If necessary, pry the blocks apart with a screwdriver. 2. Adjust the handlebar forward or rearward to the desired position. 3. Tighten the bolts. Handlebar Angle 1.
  • Page 53 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 snowmobile. Use of unapproved parts and accessories may result in: •...

  • Page 54: Traction Products

    THE PERFECT FIT Traction Products Studs Use only Polaris traction products on your snowmobile. Track warran- ties are void if track damage or failure results from improper or exces- sive stud installation or the use of non-Polaris traction products. The longest stud length recommended for your factory-installed track is 1 1/4 inches (31.75 mm).

  • Page 55: Wear Strips

    Traction Products nCarbide Skags A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain. Use carbide skags with studded tracks to help maintain proper vehicle steering and control.

  • Page 56: Pre-Ride Inspections

    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. Look for a checkmark (n) on the referenced pages to locate the pre-ride inspection items. Drive Belt Condition Steering System Recoil Rope...

  • Page 57: Pre-Ride Suspension Inspection

    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. Check suspension mounting bolts for tightness.

  • Page 58: Before Starting The Engine

    PRE-RIDE INSPECTIONS Before Starting 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. WARNING! Operating the vehicle with worn, damaged, or malfunctioning components could result in serious injury or death.

  • Page 59: Brake Lever Travel

    PRE-RIDE INSPECTIONS Before Starting the Engine n Brakes Always check the following items for proper operation before starting the engine. Brake Lever Travel Squeeze the brake lever. It should move no closer to the (1.3 cm) handgrip than 1/2I (1.3 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system.

  • Page 60: Brake Lever

    PRE-RIDE INSPECTIONS Before Starting the Engine n 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.

  • Page 61: Steering System

    Recoil Rope Inspect the recoil rope and handle for excessive wear, and make sure the knot securing the rope inside the handle is secure. If excessive wear is found, see your Polaris dealer for replacement.
  • Page 62 PRE-RIDE INSPECTIONS Start 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 Before Starting the Engine beginning on page 54.

  • Page 63: Operation

    Starting the Engine NOTICE: Engaging the starter when the engine is running WILL result in serious engine damage, especially if the transmission is in reverse. Never engage the starter when the engine is running. 1. Turn the key to the ON position. 2.

  • Page 64: Engine Break-In

    Premix the first tank of fuel with one pint of Polaris injection oil for each five gal- lons of fuel. This, in addition to the lubrication supplied by the injection system, will assure proper engine break-in.

  • Page 65: Oil Injection System

    40:1 (one pint of oil per 5 gallons of fuel) and for the first fill of the oil tank. After this initial treatment, Polaris recommends the use of VES Gold Plus Synthetic 2-cycle oil. See page 110 for the part numbers of Polaris products.

  • Page 66: Slide Rail And Track Cooling

    OPERATION Track Warm-Up WARNING! A loose track or flying debris could cause serious injury or death. Stand 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.

  • Page 67: Fuel Recommendation

    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.

  • Page 68: Fuel Resistor

    Never use deicers or additives containing methanol. Polaris recommends the use of Car- bon Clean Plus. See page 110 for the part numbers of Polaris products. If you use fuel with up to 10% ethanol (sometimes labeled “oxygen- ated”) do not add deicers or additives that contain any form of alcohol.

  • Page 69: Low Oil Level

    NOTICE: Operating the snowmobile without adequate engine lubrication can result in serious engine damage. Always check the oil level when refu- eling. Add oil as needed. The oil bottle cap is vented to allow proper oil flow. See your Polaris dealer for recommended replacement parts. OPERATION “Add”...

  • Page 70: Engine Stop Switch

    OPERATION Engine Stop Switch Push down on the engine stop switch ( ) to ground out the ignition and stop the engine quickly. Pull the switch up to the ON position to allow restarting. 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 cable or valves do not return to the normal closed position.

  • Page 71: Throttle Lever

    When these switches are disconnected, the ignition key switch must be used to shut off the engine. DO NOT continue to operate the snowmobile with the throttle safety switch disconnected. Return the snowmobile to an authorized Polaris dealer for service as soon as possi- ble. OPERATION...

  • Page 72: Emergency Stopping

    OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 66 for more information about the engine stop switch and throttle safety switch. SYSTEM Ignition Switch Brake Engine Stop Switch Throttle Safety Switch Tether Switch (Option) WHAT IT DOES...
  • Page 73 Electronic Reverse (PERCt) WARNING Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Damage will occur to the chaincase or trans- mission if shifting is attempted when the engine is operating above idle speed. •...
  • Page 74 OPERATION Electronic Reverse (PERCt) 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 sec- ond, then release. The engine will automatically reduce RPM and start a reverse rotation.

  • Page 75: Daily Storage

    Daily Storage At the end of each ride, park the snowmobile on a level surface and sup- port it at the rear with an appropriate track stand. The track should be suspended approximately 4I (10 cm) off the ground. Remove the key and cover the snowmobile. Towing For your safety, do not attempt to use a tow hitch until you've read the following warnings and understand the proper hitch functions.

  • Page 76: Maintenance

    Please read the Snowmobile Engine Emissions Limited Warranty, and read the maintenance section of your owner's manual. You are responsi- ble for ensuring that the specified maintenance is performed. Polaris recommends that you contact an authorized Polaris dealer to perform...
  • Page 77 If you're not familiar with safe service or adjustment procedures and the use of tools, or if you don't feel comfort- able performing these tasks yourself, contact an authorized Polaris dealer for service. NOTICE: Hot components can cause damage to plastic. Always make sure the exhaust system and engine have cooled before tipping the snowmo- bile on its side for service or inspection.

  • Page 78: Coolant Level

    The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. When inspection reveals the need for replacement parts, always use genuine Polaris parts, available from your Polaris dealer. Item Clutch Alignment Offset...

  • Page 79: Ignition Switch

    Periodic Maintenance Interval Table Item Hose Routing Hose Condition Fluid Leaks Brake Pads Brake Disc Parking Brakes Brake System Brake Fluid Idle RPM Throttle Lever Oil Pump Lever (synchronize) Throttle Cable Throttle Position Sensor Fuel Lines Fuel Filter (Replace) Oil Filter Oil Lines Air Box Auxiliary Shut-Off...

  • Page 80: Rear Wheel Idler Bolts

    MAINTENANCE Periodic Maintenance Interval Table Item Ski Toe Alignment Suspension Mounting Bolts Steering Fasteners Rear Suspension Fasteners Rear Suspension Bushings Suspension Shock Oil Rear Shock Threads Cooling Fins and Shroud Drive Shaft Bearing Skags (Wear Bars) Ski Saddle/Spindle Bolts Drive Chain Tension Hood and Side Panel Fasteners Rear Wheel Idler Bolts...
  • Page 81 To remove an open side panel, 1/4-Turn Fasteners pull the panel outward to release the tabs at the lower edge of the panel. Removing the hood is not recommended. Any service requiring the removal of the hood should be performed by an authorized Polaris dealer.

  • Page 82: Chaincase Oil

    73. Maintain the oil level at the top of the fill plug hole. Polaris recommends the use of Polaris Synthetic Chaincase Lube. See page 110 for the part numbers of Polaris products. Oil Level 1. Position the vehicle on a level surface.

  • Page 83: Oil Change

    Lubrication n Chaincase Oil Oil Change 1. Position the vehicle on a level surface. 2. Place a drain pan under the drain plug. Remove the drain plug. Allow the oil to drain completely. 3. Clean off all metal shavings from the plug. Install a new sealing washer on the drain plug.

  • Page 84: Throttle Cable

    Lubrication Rear Shock Body Threads Lubricate rear shock body threads seasonally. We recommend the use of Polaris Shock Thread Lubricant, a silicone spray lubricant. This lubri- cant is specifically designed for cold temperatures and high loads. Other silicone lubricants will not perform as well.

  • Page 85: Intake Filters

    Polaris dealer. Do not attempt to service the fuel pump. Fuel Filter/Fuel Lines See your Polaris dealer for replacement of the fuel filter. Have the filter replaced initially at 1000 miles (1600 km), then every 2000 miles (3200 km) thereafter.

  • Page 86: Spark Plug Recommendations

    MAINTENANCE Spark Plugs Spark Plug Recommendations A new engine can cause temporary spark plug fouling due to the preser- vative added during the assembly process. Avoid prolonged idle speeds, which cause plug fouling and carbonization. Refer to your Owner's Manual Supplement for the specific spark plug to be used in your snowmobile.

  • Page 87: Spark Plug Inspection

    Spark Plugs Spark 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.

  • Page 88: Oil Filter

    MAINTENANCE Oil Lines Inspect oil line condition every 1000 miles (1600 km). Oil Filter The oil filter is located at the side of the oil tank. Have your dealer change the oil filter and bleed the system annually or every 1000 miles (1600 km).

  • Page 89: Cooling System

    Please see your Polaris dealer. When adding or changing coolant, Polaris recommends using Premium 60/40 anti-freeze coolant, which is already premixed and ready to use. Do not dilute with water. Never exceed a 60% antifreeze/40% water mixture.

  • Page 90: Engine Overheating

    This service must be performed when the engine is cold. Ask your Polaris dealer to check the coolant when he performs the fall tune-up on your snowmobile.

  • Page 91: Bleeding The Cooling System

    Cooling System Bleeding the Cooling System CAUTION! Steam and hot liquids will cause burns 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.

  • Page 92: Exhaust System

    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 parts can cause burns. Allow adequate time for the exhaust system to cool.

  • Page 93: Drive Chain Tension

    Drive Chain Tension Check drive chain tension weekly and before each long trip. 1. Remove the side panels. 2. Rotate the driven clutch counter-clockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly.

  • Page 94: Hydraulic Brake Inspection

    3. Brake Pad Material (Replace when thickness is less than 1/ 16I/1.5 mm). Excessive Lever Travel Hydraulic brakes are self-adjust- ing, but if excessive brake pad clearance develops, bring the snowmobile to an authorized Polaris dealer for inspection and adjustment.

  • Page 95: Brake Fluid

    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 page 110 for the part numbers of Polaris products.

  • Page 96: Bleeding The Hydraulic Brake System

    MAINTENANCE Brakes Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action. Bleed the system before operating the snowmobile. WARNING! Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an accident and lead to serious injury or death.

  • Page 97: Headlight Lamp Replacement

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

  • Page 98: Clutch System

    Polaris dealer. Any unauthorized modifications to clutches, such as add- ing or removing weights, will void the warranty. NOTICE: The bushings in the weights and rollers of Polaris clutches are made of a material that may be damaged if lubricated. Do not lubricate clutch bushings.

  • Page 99: Drive Belt Condition

    MAINTENANCE Clutch System n 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.

  • Page 100: Drive Belt Deflection

    MAINTENANCE Clutch System n 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).

  • Page 101: Drive Belt Removal

    Clutch System Drive Belt Removal NOTICE: Do not attempt to remove the drive belt after operating in reverse. The snowmobile must be stopped after forward motion to prevent damage to components during belt removal. Rotate the driven clutch counter- clockwise 1/4 turn by hand to ensure forward engagement before attempting to remove the belt.

  • Page 102: Drive Belt Installation

    MAINTENANCE Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. 2. To ensure satisfactory belt life, install belts so they oper- ate in the same direction of rotation by positioning the identification numbers so that you can read them.

  • Page 103: Track Inspection

    Track Maintenance Track Inspection WARNING! Broken track rods can cause a rotating track to come off the snowmobile, which could cause serious 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 snow- mobile off the ground.
  • Page 104 MAINTENANCE Track Maintenance WARNING! Moving parts can cut and crush body parts. When performing the checks and adjustments recommended on the following pages, stay clear of all moving parts. Never perform track measurement or adjustments with the engine running. Track Tension Track adjustment is critical for proper handling.
  • Page 105 Track Maintenance Track Tension 5. Check for specified slack between the wear surface of the track clip and the plastic slider. Refer to the Track Tension Data Chart on page 100. If the track needs adjustment: 6. Loosen the rear idler shaft bolt. 7.

  • Page 106: Track Alignment/Condition

    MAINTENANCE Track Maintenance n Track 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 off the ground.

  • Page 107: Steering Inspection

    MAINTENANCE Steering System Steering Inspection Each week, or before a long ride, check all steering system fasteners and tighten if necessary.

  • Page 108: Ski Alignment

    WARNING! Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski alignment or camber adjustment. See your Polaris dealer. With the handlebars in a straight ahead position, and with vehicle weight compressing the suspension, measure from the straight edge of the skis at the center of the ski mounting bolt.

  • Page 109: Ski Skags

    Steering System n Ski Skags WARNING! Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causing serious injury or death. See your dealer's studding chart for recommended skags. If you install longer or more aggressive carbide skags than the original equipment, it may also be necessary to add track studs to maintain proper vehicle control while turning on hard-packed snow or ice.

  • Page 110: Rear Suspension

    MAINTENANCE Steering System n Rail Slide Wear Measure slide thickness at several points along the rail. 7/16 Have your dealer replace the (1.1 cm) 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 7/16I (1.1 cm).

  • Page 111: Cleaning And Preservation

    Extended Storage Off-season or extended storage of your snowmobile requires preventive measures to aid against deterioration and to prolong the useful life of many components. See page 110 for the part numbers of Polaris prod- ucts. Cleaning and Preservation Proper storage starts with cleaning, washing, and waxing the hood, side panels, chassis, and plastic parts.

  • Page 112: Electrical Connections

    MAINTENANCE Extended Storage Controls and Linkage Lubricate all bushings and cables as outlined in the Periodic Mainte- nance Table beginning on page 74. 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.

  • Page 113: Transporting The Snowmobile

    MAINTENANCE Transporting the Snowmobile Whenever the snowmobile is transported: 1. Be sure the fuel cap and oil cap are installed correctly. 2. Tie the snowmobile to the transporting unit securely using suitable straps. 3. Remove the ignition key to prevent loss.

  • Page 114: Polaris Products

    POLARIS PRODUCTS Part No. 2870791 Fogging Oil (12 oz. Aerosol) 2875035 Premium 2-Cycle Semi-Synthetic Engine Oil (qt.) (break-in only) 2875036 Premium 2-Cycle Semi-Synthetic Engine Oil (gal.) (break-in only) 2877882 VES Gold Plus Synthetic 2-Cycle Engine Oil (qt.) 2877953 VES Gold Plus Synthetic 2-Cycle Engine Oil (2 qt.) 2877883 VES Gold Plus Synthetic 2-Cycle Engine Oil (gal.)

  • Page 115: Troubleshooting

    Engine Troubleshooting Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Probable Cause Solution Erratic engine oper- Drive clutch binding ating RPM during Driven clutch mal- acceleration or load function variations Harsh drive clutch Drive belt worn or engagement...
  • Page 116 TROUBLESHOOTING Engine Troubleshooting Problem Probable Cause Solution Noise in drive Broken drive clutch system components Bearing failure/ chaincase, jackshaft, or front drive shaft Drive belt surface flat spots Drive chain loose Drive chain worn, sprocket teeth bro- Poor low RPM Worn drive belt performance Excessive belt/...
  • Page 117 Engine Troubleshooting Problem Probable Cause Solution Engine turns but fails Faulty ignition to start No fuel to engine Poor engine com- pression Engine lacks power Fouled or defective spark plug(s) Fuel filter (loss of high RPM power) Incorrect clutching Engine continually Faulty plug(s) backfires Fuel System...

  • Page 118: Suspension Troubleshooting

    TROUBLESHOOTING Suspension Troubleshooting Problem Rear suspension bottoms too easily Rides too stiff in rear Too much weight transfer when climbing Too little weight transfer when climbing Machine darts from side to side Front end pushes Steering is heavy Solution • Adjust rear shock spring (see pages 39 and 47). •...

  • Page 119: Drive Belt Troubleshooting

    Drive Belt Troubleshooting Causes Driving at low RPM Insufficient warm-up Towing at low RPM Riding with high RPM and slow speed (8000 RPM/10 MPH/16 km/h) Ice and snow build-up between track and tunnel Poor engine performance Loading snowmobiles onto trailers Clutch malfunction Slow, easy clutch engagement...

  • Page 120: Warranty

    Your dealer receives frequent updates on changes, modifications and tips on snowmobile maintenance, which may supersede information con- tained in this manual. Your dealer is also familiar with Polaris policies and pro- cedures and will be happy to assist you.
  • Page 121 Polaris warranty will provide all dealerships with a monthly updated list of all stolen units to further monitor thefts. Polaris warranty will aid in notifying the proper owner when a unit is recovered. WARRANTY...

  • Page 122: Limited Warranty

    WARRANTY Limited Warranty Polaris Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIM- ITED WARRANTY on all components of the Polaris snowmobile against defects in material or workmanship. This warranty covers the parts and labor charges for repair or replacement of defective parts that are covered by this warranty.

  • Page 123: Engine Oil

    How to Obtain Warranty Service If your snowmobile requires warranty service, you must take it to a Polaris dealer autho- rized to repair Polaris snowmobiles. When requesting warranty service you must present your copy of the Warranty Registration form to the dealer. (The cost of transportation to and from the dealer is YOUR responsibility).
  • Page 124 In order to qualify for warranty, the product must have been properly set up and tested by a Polaris Dealer (if applicable). Failure of any dealer to perform the required vehicle Pre-Delivery Inspection, perform all applicable service bulletins and have the consumer sign the PDI form prior to delivery may void the warranty.
  • Page 125 • Failures caused due to improper adjustments. • Failure due to unauthorized service. • Failures due to lack of service as required in the owner's manual or Polaris updates. This includes off-season storage as listed in the owner's manual. • Failure due to use of unauthorized parts or modifications.
  • Page 126 If Purchased From A Private Party: If you purchase a Polaris product from a private citizen outside of the country in which the vehicle was originally purchased, all warranty coverage will be denied.
  • Page 127 This emissions limited warranty is in addition to the Polaris standard limited warranty for your vehicle. Polaris Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it conforms with applica- ble U.S.
  • Page 128 Polaris dealer to perform any service that may be necessary for your vehicle. Polaris also recommends that you use only Pure Polaris parts. It is a potential violation of the Clean Air Act if a part supplied by an aftermarket parts manufacturer reduces the effectiveness of the vehicle's emission controls.

  • Page 129: 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 with an accurate log of maintenance and services performed on the snowmobile. DATE MILES (KM) 150 mi. (240 km) 500 mi.
  • Page 130 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)
  • Page 131 MAINTENANCE LOG DATE MILES TECHNICIAN SERVICE PERFORMED / COMMENTS (KM)

  • Page 132: Index

    INDEX Accessories ....49 Air Pollution ....6 Avalanches.
  • Page 133 Passenger Warning ....22 Playback Function ....33 Polaris Products and Part Numbers. 110 Preload, Front Track Shock Spring. . 46 Preload, IFS Shock Spring .
  • Page 134 INDEX Safety Labels ....21-23 Safety Symbols ....8 Set-Up Guide, Suspension .

This manual is also suitable for:

Rush 2010

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