Polaris 600 RUSH 2010 Manual
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Polaris 600 RUSH 2010 Manual

Polaris 600 RUSH 2010 Manual

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Table of Contents

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MODEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
2010 600 RUSH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
2011 600 RUSH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
2011 800 RUSH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
2011 800 SWITCHBACK ASSAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
2011 800 RMK 155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
2011 800 RMK ASSAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
2011 800 PRO RMK 155/163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
2012 600 RUSH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16
2012 800 RUSH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.18
2012 800 RUSH PRO-R LE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20
2012 600 SWITCHBACK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22
2012 800 SWITCHBACK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24
2012 SWITCHBACK ASSAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.26
2012 600 RMK 144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.28
2012 600 RMK 155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.30
2012 600 PRO RMK 155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.32
2012 800 RMK 155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.34
2012 800 RMK ASSAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.36
2012 800 PRO RMK 155/163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.38
2013 600 INDY/INDY SP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.40
2013 600 RUSH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.42
2013 800 RUSH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.44
2013 800 RUSH PRO-R LE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.46
2013 600 SWITCHBACK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.48
2013 800 SWITCHBACK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50
2013 SWITCHBACK ASSAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.52
2013 600 RMK 144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.54
2013 600 RMK 155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.56
2013 600 PRO RMK 155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.58
2013 800 RMK 155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.60
2013 800 RMK ASSAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.62
2013 800 PRO RMK 155/163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.64
SNOWMOBILE NUMBER DESIGNATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.66
VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.66
VIN NUMBER DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.66
TUNNEL DECAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.67
PUBLICATION PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.68
2010 PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.68
2011 PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.68
2012 PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.68
2013 PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.69
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.70
GENERAL REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.71
STANDARD BOLT TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.71
METRIC BOLT TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.71
GASOLINE VOLATILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.72
FUEL / OIL PREMIX RATIOS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.72
FUEL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.72
SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.73
METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.73
DECIMAL EQUIVALENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.73
MEASUREMENT CONVERSION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.74
PISTON WASH / SPARK PLUG READING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.74
General Information
CHAPTER 1
General Information
1
1.1

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Summary of Contents for Polaris 600 RUSH 2010

  • Page 1: Table Of Contents

    General Information CHAPTER 1 General Information MODEL SPECIFICATIONS ..........1.2 2010 600 RUSH.
  • Page 2 General Information MODEL SPECIFICATIONS Clutch Settings DRIVE CLUTCH P2 DRIVEN CLUTCH ALTITUDE 2010 600 RUSH meters Shift Clutch Clutch Driven Gearing (feet) Weight Spring Spring Helix Model Numbers: 0-600 10-64 23:39 - 72 S10BF6KSA / S10BF6KSL / S10BF6KEA (0-2000) 600-1200 10-62 22:39 - 72 Engine...
  • Page 3 Top Gear (Stock) Rider Weight* Bottom Gear (Stock) 90 - 150lbs. Chain (Stock) Rate lbs/in (N/mm) 120 (21) Gear Lube Polaris Synthetic (80W) Capacity (oz / ml) 9 / 266 HD RTS Spring PN: 7043585-385 Reverse System PERC Rider Weight*...

  • Page 4: 2011 600 Rush

    General Information 2011 600 RUSH Clutch Settings DRIVE CLUTCH P2 DRIVEN CLUTCH Model Numbers: ALTITUDE meters Shift Clutch Clutch Driven 600 RUSH Gearing (feet) Weight Spring Spring Helix S11BF6NSA / S11BF6NSL / S11BF6NSB / S11BF6NSM 0-600  10-64 23:39 - 72 (0-2000) 600 RUSH LX...
  • Page 5 16 Click Compression Adjustable Bottom Gear (Stock) Factory Setting** = 4 Chain (Stock) Standard RTS Spring PN: 7043572-133 Gear Lube Polaris Synthetic (80W) Rider Weight* Capacity (oz / ml) 9 / 266 120 - 250lbs. Reverse System PERC Rate lbs/in (N/mm) 190 (33.25)

  • Page 6: 2011 800 Rush

    Top Gear (Stock) Fuel Octane (R+M/2) Bottom Gear (Stock) 10% Ethanol 24 Resistor <91 Octane Chain (Stock)  (Non-Oxygenated) Gear Lube Polaris Synthetic (80W)  Capacity (oz / ml) 9 / 266  87/89/91+ Reverse System PERC  (Up to10% Oxygenated) ...
  • Page 7 General Information Track Rear Suspension Width - Inches (cm) 15 (38) Suspension Type PRO-RIDE Progressive Front Track Shock Length - Inches (cm) 121 (307) (FTS) Pitch 2.52 RUSH Fox HPG w/IFP Plies RUSH PRO-R Walker Evans w/Remote Reservoir  Lug Height - Inches (cm)  16 Click Compression Adjustable Factory Setting** = 2 RUSH...

  • Page 8: 2011 800 Switchback Assault

    General Information 2011 800 Switchback Assault 800 Switchback Assault 1.3 Clutch Settings DRIVE CLUTCH DRIVEN CLUTCH Model Numbers: ALTITUDE meters Shift Clutch Clutch Driven 800 Switchback Assault 1.3 Gearing (feet) Weight Spring Spring Helix S11CW8GSA / S11CW8GSB / S11CW8GEA 0-600 S11CW8GEB...
  • Page 9 Rear Suspension Top Gear (Stock) Bottom Gear (Stock) Suspension Type Switchback 144 Tipped Chain (Stock) Walker Evans Piggyback Gear Lube Polaris Synthetic (80W) Front Track Shock 16 Click Compression Capacity (oz / ml) 9 / 266 (FTS) Adjustable PERC Reverse System Factory Setting** = 8 FTS Spring Rate...
  • Page 10  87/89/91+ Chaincase  (Up to10% Oxygenated) Center Distance (inches) 7.53  Top Gear (Stock) Premium/Non-Ethanol Bottom Gear (Stock) 160 Resistor (Non-Oxygenated) Chain (Stock) Gear Lube Polaris Synthetic (80W) Capacity (oz / ml) 9 / 266 Reverse System PERC 1.10...
  • Page 11 General Information Track Rear Suspension Width - Inches (cm) 15 (38) Suspension Type RMK Coil-Over 155 Length - Inches (cm) 155 (393.7) Front Track Shock RydeFX Twin Tube (FTS) Pitch 2.86 Plies FTS Spring Rate 150 (26.25) lbs/in (N/mm) Lug Height - Inches (cm) 2.4 (6.1) Series 5.1 Rear Track Shock...
  • Page 12  87/89/91+  (Up to10% Oxygenated) Chaincase  Center Distance (inches) 7.53 Premium/Non-Ethanol Top Gear (Stock) 160 Resistor (Non-Oxygenated) Bottom Gear (Stock) Chain (Stock) Gear Lube Polaris Synthetic (80W) Capacity (oz / ml) 9 / 266 Reverse System PERC 1.12...
  • Page 13 General Information Track Rear Suspension Width - Inches (cm) 15 (38) Suspension Type RMK Coil-Over 155 Length - Inches (cm) 155 (393.7) Front Track Shock Walker Evans HPG w/IFP (FTS) Pitch 2.86 Plies FTS Spring Rate 180 (31.5) lbs/in (N/mm) Lug Height - Inches (cm) 2.125 (5.4) (Competition) FTS Spring Installed...
  • Page 14  Center Distance (inches) 7.53  87/89/91+ Top Gear (Stock)  (Up to10% Oxygenated) Bottom Gear (Stock)  Chain (Stock) Premium/Non-Ethanol Gear Lube Polaris Synthetic (80W) 160 Resistor (Non-Oxygenated) Capacity (oz / ml) 9 / 266 Reverse System PERC 1.14...
  • Page 15 General Information Track Rear Suspension Width - Inches (cm) 15 (38) RMK Coil-Over 155/163 Suspension Type 163= Tipped Rail 155 (393.7) Length - Inches (cm) 163 (414) Front Track Shock Walker Evans HPG w/IFP (FTS) Pitch 2.86 Plies FTS Spring Rate 150 (26.25) lbs/in (N/mm) Lug Height - Inches (cm)

  • Page 16: 2012 600 Rush

    General Information 2012 600 RUSH Clutch Settings DRIVE CLUTCH P2 DRIVEN CLUTCH Model Numbers: ALTITUDE meters Shift Clutch Clutch Driven 600 RUSH Gearing (feet) Weight Spring Spring Helix S12BF6NSA / S12BF6NSL 0-600  10-64 23:39 - 72 (0-2000) 600 RUSH PRO-R 600-1200...
  • Page 17 16 Click Compression Adjustable Bottom Gear (Stock) Factory Setting** = 4 Chain (Stock) Standard RTS Spring PN: 7043195-133 Gear Lube Polaris Synthetic (80W) Rider Weight* Capacity (oz / ml) 9 / 266 120 - 260lbs. Reverse System PERC Rate lbs/in (N/mm) 170 (29.75)

  • Page 18: 2012 800 Rush

    Center Distance (inches) 7.53  (Non-Oxygenated) Top Gear (Stock)  Bottom Gear (Stock)  87/89/91+ Chain (Stock)  (Up to10% Oxygenated) Gear Lube Polaris Synthetic (80W)  Capacity (oz / ml) 9 / 266 Premium/Non-Ethanol Reverse System PERC 160 Resistor (Non-Oxygenated) 1.18...
  • Page 19 General Information Track Rear Suspension Width - Inches (cm) 15 (38) Suspension Type PRO-RIDE Progressive Front Track Shock Length - Inches (cm) 121 (307) (FTS) Pitch 2.52 Base Fox HPG w/IFP Plies PRO-R Walker Evans w/Remote Reservoir  Lug Height - Inches (cm)  16 Click Compression Adjustable Factory Setting** = 2 Base...
  • Page 20  87/89/91+  (Up to10% Oxygenated) Chaincase  Center Distance (inches) 7.53 Premium/Non-Ethanol Top Gear (Stock) 160 Resistor (Non-Oxygenated) Bottom Gear (Stock) Chain (Stock) Gear Lube Polaris Synthetic (80W) Capacity (oz / ml) 9 / 266 Reverse System PERC 1.20...
  • Page 21 General Information Track Rear Suspension Width - Inches (cm) 15 (38) Suspension Type PRO-RIDE Progressive Length - Inches (cm) 121 (307) Walker Evans w/Remote Front Track Shock Reservoir Pitch 2.52 (FTS) 16 Click Compression  Plies Adjustable Lug Height - Inches (cm) 1.352 (3.43) (Cobra) Factory Setting** = 2 Track tension sag in/mm...

  • Page 22: 2012 600 Switchback

    General Information 2012 600 Switchback Clutch Settings DRIVE CLUTCH P2 DRIVEN CLUTCH Model Numbers: ALTITUDE meters Shift Clutch Clutch Driven 600 Switchback Gearing (feet) Weight Spring Spring Helix S12BR6NSA / S12BR6NSL 0-600 10-64 23:39 - 72 (0-2000) 600 Switchback Adventure 600-1200...
  • Page 23 Top Gear (Stock) w/Remote Reservoir  Bottom Gear (Stock) 16 Click Compression Adjustable Chain (Stock) Factory Setting** = 4 Gear Lube Polaris Synthetic (80W) Standard RTS Spring PN: 7043160-133 Capacity (oz / ml) 9 / 266 Rider Weight* Reverse System PERC 120 - 260lbs....

  • Page 24: 2012 800 Switchback

    Top Gear (Stock) Fuel Octane (R+M/2) Bottom Gear (Stock) 10% Ethanol 24 Resistor <91 Octane Chain (Stock)  (Non-Oxygenated) Gear Lube Polaris Synthetic (80W)  Capacity (oz / ml) 9 / 266  87/89/91+ Reverse System PERC  (Up to10% Oxygenated) ...
  • Page 25 General Information Track Rear Suspension Width - Inches (cm) 15 (38) Suspension Type PRO-RIDE Progressive Length - Inches (cm) 136 (345.4) Front Track Shock (FTS) Pitch 2.52 Base Fox HPG w/IFP Plies Adventure/PRO-R Walker Evans w/Remote Lug Height - Inches (cm)  ...

  • Page 26: 2012 Switchback Assault

    General Information 2012 Switchback Assault Switchback Assault 1.3 Clutch Settings DRIVE CLUTCH DRIVEN CLUTCH Model Numbers: ALTITUDE meters Shift Clutch Clutch Driven Switchback Assault 1.3 Gearing (feet) Weight Spring Spring Helix S12CW8GSA / S12CW8GSL 0-600  10-66 (0-2000) Switchback Assault 2.0 BLU/BLK 600-1200...
  • Page 27 7.53 Top Gear (Stock) Rear Suspension Bottom Gear (Stock) Chain (Stock) Suspension Type Switchback 144 Tipped Gear Lube Polaris Synthetic (80W) Walker Evans Piggyback Capacity (oz / ml) 9 / 266 Front Track Shock 16 Click Compression PERC Reverse System...
  • Page 28 General Information 2012 600 RMK 144 Clutch Settings DRIVE CLUTCH DRIVEN CLUTCH Model Numbers: ALTITUDE meters Shift Clutch Clutch Driven S12CK6GSA / S12CK6GSL / S12CK6GEA Gearing (feet) Weight Spring Spring Helix 0-600 Engine 10-64 (0-2000) 600-1200 Liberty Liquid-Cooled / 10-62 Engine Type (2000-4000) Case Reed Induction...
  • Page 29 7.53 Rear Track Shock Top Gear (Stock) RydeAFX Twin Tube (RTS) Bottom Gear (Stock) Chain (Stock) .359/77° Gear Lube Polaris Synthetic (80W) Torsion Springs LH=7041629-329 Capacity (oz / ml) 9 / 266 RH=7041630-329 PERC Reverse System Rear Travel 13 (33)
  • Page 30 General Information 2012 600 RMK 155 Clutch Settings DRIVE CLUTCH DRIVEN CLUTCH Model Numbers: ALTITUDE meters Shift Clutch Clutch Driven S12CM6GSA / S12CM6GSL Gearing (feet) Weight Spring Spring Helix 0-600 Engine 10-64 (0-2000) 600-1200 Liberty Liquid-Cooled / 10-62 Engine Type (2000-4000) Case Reed Induction 1200-1800...
  • Page 31 210 (36.75) Top Gear (Stock) Installed Length In. (cm) Bottom Gear (Stock) (Track off ground) Chain (Stock) Rider Weight* Gear Lube Polaris Synthetic (80W) <160lbs./72kg 10-3/4" (27.3) Capacity (oz / ml) 9 / 266 160-220lbs./72-99kg 10-1/4" (26) PERC Reverse System 220-280lbs./99-127kg...
  • Page 32 General Information 2012 600 PRO RMK 155 Clutch Settings DRIVE CLUTCH DRIVEN CLUTCH Model Numbers: ALTITUDE meters Shift Clutch Clutch Driven S12CG6GSA / S12CG6GSL / S12CG6GEA Gearing (feet) Weight Spring Spring Helix 0-600 Engine 10-64 (0-2000) 600-1200 Liberty Liquid-Cooled / 10-62 Engine Type (2000-4000)
  • Page 33 Top Gear (Stock) Walker Evans HPG w/IFP (RTS) Bottom Gear (Stock) Chain (Stock) Standard RTS Spring PN: 7043714-133 Gear Lube Polaris Synthetic (80W) Rate lbs/in (N/mm) 210 (36.75) Capacity (oz / ml) 9 / 266 Installed Length In. (cm) PERC Reverse System (Track off ground)...
  • Page 34  87/89/91+  (Up to10% Oxygenated) Chaincase  Center Distance (inches) 7.53 Premium/Non-Ethanol Top Gear (Stock) 160 Resistor (Non-Oxygenated) Bottom Gear (Stock) Chain (Stock) Gear Lube Polaris Synthetic (80W) Capacity (oz / ml) 9 / 266 Reverse System PERC 1.34...
  • Page 35 General Information Track Rear Suspension Width - Inches (cm) 15 (38) Suspension Type RMK Coil-Over 155 Length - Inches (cm) 155 (393.7) Front Track Shock RydeFX Twin Tube (FTS) Pitch 2.86 Plies FTS Spring Rate 150 (26.25) lbs/in (N/mm) Lug Height - Inches (cm) 2.4 (6.1) Series 5.1 Rear Track Shock...
  • Page 36  87/89/91+ Chaincase  (Up to10% Oxygenated) Center Distance (inches) 7.53  Top Gear (Stock) Premium/Non-Ethanol Bottom Gear (Stock) 160 Resistor (Non-Oxygenated) Chain (Stock) Gear Lube Polaris Synthetic (80W) Capacity (oz / ml) 9 / 266 Reverse System PERC 1.36...
  • Page 37 General Information Track Rear Suspension Width - Inches (cm) 15 (38) Suspension Type RMK Coil-Over 155 Length - Inches (cm) 155 (393.7) Front Track Shock Walker Evans HPG w/IFP (FTS) Pitch 2.86 Plies FTS Spring Rate 180 (31.5) lbs/in (N/mm) Lug Height - Inches (cm) ...

  • Page 38: 2012 800 Pro Rmk 155/163

    10% Ethanol 24 Resistor <91 Octane Top Gear (Stock)  (Non-Oxygenated) Bottom Gear (Stock)  Chain (Stock)  87/89/91+ Gear Lube Polaris Synthetic (80W)  (Up to10% Oxygenated) Capacity (oz / ml) 9 / 266  Reverse System PERC Premium/Non-Ethanol 160 Resistor (Non-Oxygenated)
  • Page 39 General Information Track Rear Suspension Width - Inches (cm) 15 (38) Suspension Type RMK Coil-Over 155/163 155 (393.7) Front Track Shock Length - Inches (cm) Walker Evans HPG w/IFP 163 (414) (FTS) Pitch 2.86 FTS Spring Rate 150 (26.25) Plies lbs/in (N/mm) Lug Height - Inches (cm) 2.4 (6.1) Series 5.1...

  • Page 40: 2013 600 Indy/Indy Sp

    General Information 2013 600 INDY/INDY SP Clutch Settings DRIVE CLUTCH P2 TABBED DRIVEN CLUTCH Model Numbers: ALTITUDE meters Shift Clutch Clutch Driven 600 INDY Gearing (feet) Weight Spring Spring Helix S13CB6GSA / S13CB6GSL 0-600 INTERNATIONAL: S13CB6GEA 10-64 (0-2000) 600 INDY SP 600-1200...
  • Page 41 Center Distance (inches) 7.53 Top Gear (Stock) Rear Suspension Bottom Gear (Stock) Suspension Type INDY 121 Chain (Stock) Gear Lube Polaris Synthetic (80W) Front Track Shock Capacity (oz / ml) 9 / 266 (FTS) PERC INDY RydeFX MPV Reverse System...

  • Page 42: 2013 600 Rush

    General Information 2013 600 RUSH Clutch Settings DRIVE CLUTCH P2 DRIVEN CLUTCH Model Numbers: ALTITUDE meters Shift Clutch Clutch Driven 600 RUSH Gearing (feet) Weight Spring Spring Helix S13BF6GSA / S13BF6GSL 0-600 600 RUSH PRO-R 10-64 (0-2000) S13BP6GSA / S13BP6GSL / S13BP6GSM 600-1200...
  • Page 43 Top Gear (Stock) Standard RTS Spring PN: 7043195-133 Bottom Gear (Stock) Rider Weight* Chain (Stock) 120 - 260lbs. Gear Lube Polaris Synthetic (80W) Rate lbs/in (N/mm) 170 (29.75) Capacity (oz / ml) 9 / 266 Reverse System PERC LW RTS Spring...
  • Page 44  Center Distance (inches) 7.53  87/89/91+ Top Gear (Stock)  (Up to10% Oxygenated) Bottom Gear (Stock)  Chain (Stock) Premium Mode  Gear Lube Polaris Synthetic (80W) (Non-Oxygenated) Capacity (oz / ml) 9 / 266 Reverse System PERC 1.44...
  • Page 45 General Information Track Rear Suspension Width - Inches (cm) 15 (38) Suspension Type PRO-RIDE Progressive Front Track Shock Length - Inches (cm) 121 (307) (FTS) Pitch 2.52 Base Fox HPG w/IFP Plies PRO-R Walker Evans w/Remote Reservoir  Lug Height - Inches (cm)  16 Click Compression Adjustable Factory Setting** = 2 Base...
  • Page 46  87/89/91+  (Up to10% Oxygenated) Chaincase  Center Distance (inches) 7.53 Premium Mode  Top Gear (Stock) (Non-Oxygenated) Bottom Gear (Stock) Chain (Stock) Gear Lube Polaris Synthetic (80W) Capacity (oz / ml) 9 / 266 Reverse System PERC 1.46...
  • Page 47 General Information Track Rear Suspension Width - Inches (cm) 15 (38) Suspension Type PRO-RIDE Progressive Length - Inches (cm) 121 (307) Front Track Shock Walker Evans w/Remote (FTS) Reservoir Pitch 2.52  16 Click Compression Plies  Adjustable Lug Height - Inches (cm) Factory Setting** = 2 PRO-R LE...

  • Page 48: 2013 600 Switchback

    General Information 2013 600 Switchback Clutch Settings DRIVE CLUTCH P2 DRIVEN CLUTCH Model Numbers: ALTITUDE meters Shift Clutch Clutch Driven 600 Switchback Gearing (feet) Weight Spring Spring Helix S13BR6GSA / S13BR6GSL 0-600 600 Switchback Adventure 10-64 (0-2000) S13BA6GSL 600-1200 10-62 600 Switchback PRO-R...
  • Page 49 Top Gear (Stock) Factory Setting** = 4 Bottom Gear (Stock) Standard RTS Spring PN: 7043160-133 Chain (Stock) Rider Weight* Gear Lube Polaris Synthetic (80W) 120 - 260lbs. Capacity (oz / ml) 9 / 266 Rate lbs/in (N/mm) 150 (26.25) Reverse System PERC LW RTS Spring...

  • Page 50: 2013 800 Switchback

    Fuel Pressure - PSI (bar) 58-60 (4.0-4.1) Bottom Gear (Stock) Fuel Octane (R+M/2) <91 Octane Chain (Stock) 10% Ethanol Mode (Non-Oxygenated) Gear Lube Polaris Synthetic (80W)  Capacity (oz / ml) 9 / 266  87/89/91+ Reverse System PERC ...
  • Page 51 General Information Track Rear Suspension Width - Inches (cm) 15 (38) Suspension Type PRO-RIDE Progressive Length - Inches (cm) 136 (345.4) Front Track Shock (FTS) Pitch 2.52 Base Fox HPG w/IFP Plies Adventure/PRO-R Walker Evans w/Remote Lug Height - Inches (cm)  ...

  • Page 52: 2013 Switchback Assault

    General Information 2013 Switchback Assault Switchback Assault 1.3 Clutch Settings DRIVE CLUTCH DRIVEN CLUTCH Model Numbers: ALTITUDE meters Shift Clutch Clutch Driven Switchback Assault 1.3 Gearing (feet) Weight Spring Spring Helix S13CW8GSA S13CW8GSB S13CW8GSL 0-600 S13CW8GSM 10-66 (0-2000) Switchback Assault 2.0 BLU/BLK 600-1200...
  • Page 53 Rear Suspension Top Gear (Stock) Suspension Type Switchback 144 Tipped Bottom Gear (Stock) Chain (Stock) Walker Evans Piggyback Gear Lube Polaris Synthetic (80W) Front Track Shock 16 Click Compression Capacity (oz / ml) 9 / 266 (FTS) Adjustable PERC Factory Setting** = 8 Reverse System FTS Spring Rate...

  • Page 54: 2013 600 Rmk 144

    General Information 2013 600 RMK 144 Clutch Settings DRIVE CLUTCH DRIVEN CLUTCH Model Numbers: ALTITUDE meters Shift Clutch Clutch Driven S13CK6GSA / S13CK6GSL Gearing (feet) Weight Spring Spring Helix INTERNATIONAL: S13CK6GEA / S13CK6GEL 0-450 10-64 (0-1500) Engine 450-900 10-62 (1500-3000) Liberty Liquid-Cooled / Engine Type 900-1500...
  • Page 55 Suspension Type RMK144 Tipped Bottom Gear (Stock) Front Track Shock RydeFX Twin Tube Chain (Stock) (FTS) Gear Lube Polaris Synthetic (80W) FTS Spring Rate Capacity (oz / ml) 9 / 266 170 (21 - 54.25) lbs/in (N/mm) PERC Reverse System...

  • Page 56: 2013 600 Rmk 155

    General Information 2013 600 RMK 155 Clutch Settings DRIVE CLUTCH DRIVEN CLUTCH Model Numbers: ALTITUDE meters Shift Clutch Clutch Driven S13CM6GSA / S13CM6GSL Gearing (feet) Weight Spring Spring Helix INTERNATIONAL: S13CM6GEA 0-450 10-64 (0-1500) Engine 450-900 10-62 (1500-3000) Liberty Liquid-Cooled / Engine Type 900-1500...
  • Page 57 210 (36.75) Top Gear (Stock) Installed Length In. (cm) Bottom Gear (Stock) (Track off ground) Chain (Stock) Rider Weight* Gear Lube Polaris Synthetic (80W) <160lbs./72kg 10-3/4" (27.3) Capacity (oz / ml) 9 / 266 160-220lbs./72-99kg 10-1/4" (26) PERC Reverse System 220-280lbs./99-127kg...

  • Page 58: 2013 600 Pro Rmk 155

    General Information 2013 600 PRO RMK 155 Clutch Settings DRIVE CLUTCH DRIVEN CLUTCH Model Numbers: ALTITUDE meters Shift Clutch Clutch Driven Belt S13CG6GSA / S13CG6GSL (feet) Weight Spring Spring Helix Gearing INTERNATIONAL: S13CG6GEA 0-450 10-64 (0-1500) Engine 450-900 10-62 (1500-3000) Liberty Liquid-Cooled / Engine Type 900-1500...
  • Page 59 General Information General Front Suspension 1.95  0.31 (4.3  .8) Width (in/cm) 46.5 / 118.1 Camber Inches (cm) Length (in/cm) 129/327.7 Toe Out - Inches 0 -1/8 (0 - 3) (mm) Height (in/cm) 51 / 129.5 Estimated Dry Weight (lb/kg) 431/195.5 Rear Suspension Fuel (Gallons / Liters)
  • Page 60  87/89/91+  (Up to10% Oxygenated) Chaincase  Center Distance (inches) 7.53 Premium Mode  Top Gear (Stock) (Non-Oxygenated) Bottom Gear (Stock) Chain (Stock) Gear Lube Polaris Synthetic (80W) Capacity (oz / ml) 9 / 266 Reverse System PERC 1.60...
  • Page 61 General Information Track Rear Suspension Width - Inches (cm) 15 (38) Suspension Type RMK Coil-Over 155 Length - Inches (cm) 155 (393.7) Front Track Shock RydeFX Twin Tube (FTS) Pitch 2.86 Plies FTS Spring Rate 150 (26.25) lbs/in (N/mm) Lug Height - Inches (cm) 2.4 (6.1) Series 5.1 Rear Track Shock...
  • Page 62  87/89/91+ Chaincase  (Up to10% Oxygenated) Center Distance (inches) 7.53  Top Gear (Stock) Premium Mode  Bottom Gear (Stock) (Non-Oxygenated) Chain (Stock) Gear Lube Polaris Synthetic (80W) Capacity (oz / ml) 9 / 266 Reverse System PERC 1.62...
  • Page 63 General Information Track Rear Suspension Width - Inches (cm) 15 (38) Suspension Type RMK Coil-Over 155 Length - Inches (cm) 155 (393.7) Front Track Shock Walker Evans HPG w/IFP (FTS) Pitch 2.86 Plies 2 (Competition) FTS Spring Rate 180 (31.5) 1 (Series 5.1) lbs/in (N/mm) Lug Height - Inches (cm) ...

  • Page 64: 2013 800 Pro Rmk 155/163

    General Information 2013 800 PRO RMK 155/163 Clutch Settings DRIVE CLUTCH DRIVEN CLUTCH Model Numbers: ALTITUDE meters Shift Clutch Clutch Driven Belt 800 PRO RMK 155 (feet) Weight Spring Spring Helix Gearing S13CG8GSA S13CG8GSL S13CG8GSB 0-600 S13CG8GSM / S13CG8GSC / S13CG8GSP 10-68 (0-2000) INTERNATIONAL: S13CG8GEA / S13CG8GEB...
  • Page 65 General Information Track Rear Suspension Width - Inches (cm) 15 (38) Suspension Type RMK Coil-Over 155/163 155 (393.7) Front Track Shock Length - Inches (cm) Walker Evans HPG w/IFP 163 (414) (FTS) Pitch 2.86 FTS Spring Rate 150 (26.25) Plies lbs/in (N/mm) Lug Height - Inches (cm) 2.4 (6.1) Series 5.1...

  • Page 66: Snowmobile Number Designations

    General Information SNOWMOBILE NUMBER DESIGNATIONS Model Number Designation Example: S10BF6KSA MODEL OPTION GROUP MODEL LINE MODEL TYPE ENGINE MODIFIER YEAR IDENTIFIER IDENTIFIER 1st digit 2/3rd digit 4th digit* 5th digit* 6th/7th digits* 8th digit 9th digit** A = Base Adventure B = 121 Indy C = PRO-R Adv.

  • Page 67: Tunnel Decal

    General Information Tunnel Decal machine model and V.I.N. number identification decal is located on the right front side of the tunnel. The V.I.N. (2) The Tunnel Decal has the Model Number (1), V.I.N. number is permanently stamped into the tunnel. The Number (2), and the Manufactured Date (3).

  • Page 68: Publication Part Numbers

    General Information PUBLICATION PART NUMBERS 2010 Publications MODEL OWNER'S MANUAL SUPPLEMENT PARTS BOOK 9922279 600 RUSH 9922276 9922280 9922648 (S10BF6KSL) 2011 Publications MODEL OWNER'S MANUAL SUPPLEMENT PARTS BOOK 9922839 (RUSH) 9922830 (RUSH LX) 9922831 (RUSH/LX) 600 RUSH 9922835 (PRO-R Retro LX) 9922836 (PRO-R) 9922841 (PRO-R) 9922829...
  • Page 69 General Information 2013 Publications MODEL OWNER'S MANUAL PARTS BOOK 600 INDY Models 9923868 9923865 600 RUSH - 9923846 800 RUSH - 9923850 600/800 RUSH Models 9923844 600 RUSH PRO-R - 9923851 800 RUSH PRO-R - 9923852 600 Switchback - 9923857 800 Switchback - 9923858 600/800 Switchback Models 9923836...

  • Page 70: Special Tools

    General Information SPECIAL TOOLS Tools when servicing any Polaris product. Dealers may order special tools through Polaris’ official tool supplier, Special tools may be required while servicing this vehicle. SPX Corporation, by phone at 1-800-328-6657 or on-line Some of the tools listed or depicted are mandatory, while at http://polaris.spx.com/.

  • Page 71: General Reference

    General Information GENERAL REFERENCE Standard Bolt Torque Specification Grade 2 Grade 8 Grade 5 Grade 2 Grade 5 Grade 8 Bolt Size ft-lbs (Nm) ft-lbs (Nm) ft-lbs (Nm) 1/4-20 5 (7) 8 (11) 12 (16) 1/4-28 6 (8) 10 (14) 14 (19) 5/16-18 11 (15)

  • Page 72: Gasoline Volatility

    This will cause warm If you use non-ethanol fuel (sometimes labeled “non- engine driveability problems and hard starting when oxygenated”), Polaris recommends the regular use of a warm. isopropyl-based fuel system deicer. Add one to two ounces per gallon (8-16 ml per liter) of gasoline to prevent damage resulting from fuel system icing.

  • Page 73: Sae Tap Drill Sizes

    General Information SAE Tap Drill Sizes Decimal Equivalents 1/64 ................0156 Thread Size/ Drill Size Thread Size / Drill Size ..... 1/32 ........0312 ..1 mm= .0394" #0-80 3/64 1/2-13 27/64 3/64 ..........0469 #1-64 1/2-20 29/64 ..... 1/16 ........0625 5/64 ........
  • Page 74 General Information Measurement Conversion Chart Piston Wash / Spark Plug Reading Changing temperature, barometer, altitude, and fuel NIT OF supply are just a few of the factors that can affect the day ULTIPLIED BY ONVERTS TO EASURE to day performance of your engine. That is why using Exhaust Gas Temperatures (EGT) are important for ft-lbs x 12...
  • Page 75 Maintenance CHAPTER 2 Maintenance PERIODIC MAINTENANCE ..........2.2 PERIODIC MAINTENANCE SCHEDULE .
  • Page 76 Maintenance STEERING / SUSPENSION MAINTENANCE....... . . 2.29 HANDLEBARS ............2.29 ADJUSTABLE RISER.

  • Page 77: Periodic Maintenance

    Maintenance PERIODIC MAINTENANCE Periodic Maintenance Schedule Periodic Maintenance Table Frequency / Intervals Item 150 mi. 500 mi. 1000 mi. 2000 mi. Pre- (240 km) (800 km) (1600 km) (3200 km) Season Drive / Driven Clutch Clutch Alignment / Offset Drive Belt Condition / Ride Out Pre-Ride Inspection Drive / Driven Clutch Condition Drive Belt Tension...
  • Page 78 Maintenance Periodic Maintenance Table Frequency / Intervals Item 150 mi. 500 mi. 1000 mi. 2000 mi. Pre- (240 km) (800 km) (1600 km) (3200 km) Season Fuel Filter Replace every 2,000 miles (3,200km) or every 2 years. Throttle Lever / Throttle Cable Fuel / Vent Hoses Oil Pump Adjustment Oil Hoses...

  • Page 79: Maintenance Products

    Maintenance MAINTENANCE PRODUCTS DESCRIPTION PART NUMBER  Engine Oils / Lubricants / Misc. Fuel Stabilizer Quart 2870652 2.5 Gallon 2872280 DESCRIPTION PART NUMBER Three Bond Sealant 5oz. 2871557  Premium 2-Cycle Semi-Synthetic Oil  Loctite® 242™ 2871950 (Use for engine break-in.) Quart...

  • Page 80: Break-In Procedures

    1. Remove the vent hose from the EV base fitting. pistons, crankshaft, cylinder, etc.). Polaris semi-synthetic 2. On the MAG VES assembly, remove the two engine oil will seat the rings faster than when using Polaris fasteners that secure the valve assembly to the VES Gold Plus oil.
  • Page 81 Maintenance 7. Inspection: 9. Inspect the VES gas ports on the cylinder(s) for blockage. Remove the spark plugs and use a piston • Inspect the guillotine for signs of damage. Replace inspection light to illuminate the port(s). guillotine if damage is found. Inspect the cylinder and piston for damage if guillotine is damaged.

  • Page 82: Spark Plugs

    Inspect the engine, throttle body performance, Polaris recommends using Polaris VES boots, etc. for air leaks. Gold Plus Synthetic Two-Stroke engine oil. Never mix different brands of engine oil. If the spark plug electrode/insulator is black, oily, or shows heavy soot, the engine may be running rich.

  • Page 83: Spark Plug Caps/Spark Plug Terminals

    Maintenance Spark Plug Caps/Spark Plug Terminals Spark Plug Wire Maintenance/Routing Inspect the spark plug caps when performing spark plug Inspect each spark plug wire and the routing of both high maintenance. tension wires when performing spark plug maintenance. Visually inspect the terminal ring inside the cap and the Replace damaged wires/ignition coils if found.

  • Page 84: Surge Tank

    Add more Recommended Coolant coolant if required. 13. Reinstall the surge tank cap, hood, and engine Use Polaris Premium 60/40 pre-mixed antifreeze. This premium antifreeze is rated for temperatures down to compartment door panels. -62°F (-52°C).

  • Page 85: Engine Mount Bolt Re-Torque

    Maintenance Engine Mount Bolt Re-Torque MAG Engine Mount Bolts NOTE: The engine mount bolt maintenance procedure only applies to 2010-2011 Pro-Ride vehicles using the original 14mm head diameter bolts.  2012-later models and 2010-2011 engine mount bolt service parts use 16mm head diameter bolts and only require periodic visual inspection.

  • Page 86: Oil Pump Adjustment

    Maintenance Oil Pump Adjustment 3. Access to the oil pump for inspection is between the drive and driven clutches. 1. Verify the throttle cable free play is set to specification (.010 - .030) and the throttle lever is synchronized to LOOK THROUGH THIS OPENING the throttle plates.

  • Page 87: Oil Pump Bleeding

    Maintenance Oil Injection Hose Priming NOTE: If the linkage arm comes off of the lever or adjuster arm, verify the oil pump lever arm has not rotated over-center prior to reinstalling the linkage. CAUTION Oil Pump Bleeding FAILURE TO PROPERLY PRIME THE OIL PUMP MAY CAUSE SEVERE ENGINE DAMAGE.

  • Page 88: Oil Tank/Clutch Cover Service

    Maintenance Oil Tank/Clutch Cover Service 11. Installation is the reverse of removal. After installing the supply hose on to the filter and installing the The oil tank is mounted to the clutch cover assembly. The clamp, hold the oil tank high in the engine oil tank/clutch cover assembly can be removed from the compartment with the supply hose pointed down to vehicle to access components within the engine...

  • Page 89: Oil Filter Service

    Maintenance Oil Filter Service 5. Install oil tank/supply hose with clamp. Hold the tank high in the engine compartment with the supply hose The oil filter is located near the oil tank on 600 models, and pointed down to allow the trapped air to bleed between the reed tracks on 800 models.

  • Page 90: Oil Supply Hose Routing/Panduit Strap

    Maintenance 10. Loosen the two throttle body gear clamps and remove 23. Reinstall the driven clutch and drive belt. Tighten drive the throttle body from the adapter plate and secure it clutch fastener to 17ft-lbs (23 Nm). to the steering drag link. Oil Supply Hose Routing/Panduit Strap 11.

  • Page 91: Pvt System

    Maintenance PVT SYSTEM 4. The measurement should be 1-1/4" (3.2cm). Belt Deflection Inspection = In. / mm. Excessive belt deflection is when the belt is too long or the center distance is too short. The initial starting ratio will be Belt Deflection: 1.25"...

  • Page 92: Clutch Alignment/Offset

    Maintenance Clutch Alignment/Offset Driven Clutch Offset/Shim Washers The drive and driven clutches are offset from each other. This offset is controlled by the number and thickness of Offset Washers washers installed on the jackshaft behind the driven 16 Gauge Bushing=7556509 (QTY.1) clutch.

  • Page 93: Adjusting Engine Mount Bolts/Engine Alignment

    Maintenance Adjusting Engine Mount Bolts/Engine 4. Once clutch alignment is set, tighten the engine mount Alignment bolts to specification in the sequence shown in the illustration. Minor adjustments to the engine mount bolts and MAG- front engine mount can be performed if the alignment tool indicates major clutch mis-alignment.

  • Page 94: Fuel/Intake System

    Maintenance FUEL/INTAKE SYSTEM 10. If the filter bracket was removed for any reason, note that the fuel return hose p-clamp is installed behind the filter bracket. Fuel Filter - DC-CFI-4 Models 11. Inspect the hoses making sure none are worn or damaged.
  • Page 95 Maintenance 7. Depressurize the fuel system. Remove the filter from 11. Carefully remove the fuel hose fitting from the fuel rail. the airbox bracket. Have a clean shop rag at hand to absorb any fuel that leaks from the fitting. Dispose of rag properly when FUEL RETURN HOSE CLOSE COVER TO finished.

  • Page 96: Fuel Hose Inspection

    Maintenance 16. On 2013 models, install the supply hose connector Fuel Hose Inspection onto the fuel pump flange fitting. Once seated, push Inspect all fuel hoses as part of periodic maintenance. lock in to secure the connector. Verify an audible Replace any fuel hose if the inner rubber core show signs “click”...

  • Page 97: Fuel Tank Vent Hose Routing

    Maintenance Fuel Tank Vent Hose Routing Air Box/Pre-Filters Route the vent hose into the left-rear over structure tube. Inspect the air intake system as outlined in the periodic Verify the hose is not kinked. maintenance table. Replace cracked, broken, or missing parts.

  • Page 98: Air Box Servicing

    Maintenance 2011 and later models feature an air box with a revised Air Box Servicing intake tube to reduce noise and a trumpet plate that is The air box can be removed from the engine compartment screwed to the air box base. by disassembling the individual components.

  • Page 99: Chassis

    Maintenance CHASSIS To remove the hood, follow these steps: 1. Remove both door panels. Door/Hood Removal and Installation 2. Using a T40 Torx driver, remove the two screws To remove the door panels, follow these steps: securing the hood to the steering post. 1.
  • Page 100 Maintenance 7. When installing the hood on 2010-2012 models, verify slots at the rear of the hood. the hood harness connector is routed under the over structure tube. PLENUM SLOT HARNESS CONNECTOR CONSOLE TAB NOTE: Failure to properly install the console tabs NOTE: The hood harness connector must be routed into the hood plenum may not allow the hood to seat under the over structure tube to prevent the wires...

  • Page 101: Chain Case Oil Level Check

    Fill chaincase with 80W synthetic chaincase lubricant at the fill plug location until the oil level is at the base of the threads. Chaincase Oil Capacity = 9oz. (266 ml) Recommended Lubricant: Chaincase = Polaris 80W Synthetic Chaincase Lubricant 2.27...

  • Page 102: Chain Case Fastener Re-Torque

    Maintenance Chain Case Fastener Re-Torque QuickDrive™ Low Inertia System NOTE: This maintenance procedure only applies to The QuickDrive™ Low Inertia System requires periodic 2010-2011 models. 2012-later models feature chain inspection as outlined in the periodic maintenance table. cases that are bonded to the chassis. Belt replacement is required every 2,000 miles (3,200 km).

  • Page 103: Brake System Maintenance

    Inspect the reservoir to be sure it contains the correct amount of fluid. Use only Polaris DOT 4 high temperature brake fluid. Change fluid every 2 years or whenever the fluid is dark or contamination is suspected.

  • Page 104: Throttle Cable Routing

    Maintenance NOTE: Never use the in-line adjuster to adjust engine STEERING / SUSPENSION idle speed. Never adjust the cable so that the throttle MAINTENANCE plate cam on the throttle body no longer rests against the idle air gap screw. Handlebars Turning the in-line adjuster inwards (clockwise) will Periodically inspect the torque of the handlebar clamp increase throttle lever free-play.

  • Page 105: Adjustable Riser

    Maintenance Ski/Ski Skag Fasteners 3. Adjust handlebars to desired position. Verify the wiring harness, brake hose, and throttle cable do not Periodically inspect the ski-to-spindle fasteners for proper kink. torque. NOTE: Verify “FWD” printed on riser faces front of SKI STOP (“FRONT” TO SKI TIP) snowmobile 4.

  • Page 106: Track Tension

    Maintenance Track Tension 5. Measure the distance between the rail slider and the track. The measurement should fall within the Track tension is critical for maintaining correct suspension measurement range for the appropriate vehicle. operation. If the track tension is too loose, the track may bunch-up at the rail tips, or slip (ratchet).

  • Page 107: Track Alignment

    Maintenance Track Alignment 9. After any adjustments are complete, be sure to torque the locknuts to specification. NOTE: Track alignment affects track tension. Misalignment of the track will cause excessive wear to  the track, rail slides, and rail. Excessive rail slide wear occurs due to running in Adjuster Lock Nuts: 33 ft-lbs (45 Nm) inadequate snow conditions.

  • Page 108: Suspension Lubrication

    Progressive 121 Switchback/RMK 144 GREASE ZERK BUSHING LOCATION Suspension Lubrication RMK Coil Over 155/163 Lubricate the rear suspension pivot shafts with Polaris Premium All Season Grease as outlined in the periodic maintenance table. Progressive 121/136 GREASE ZERK Conventional 121 GREASE ZERK GREASE ZERK 2.34...

  • Page 109: Electrical Systems

    Maintenance ELECTRICAL SYSTEMS Headlight Bulb Replacement NOTE: Do not touch the bulb with your fingers. The grease from body oil will cause a hot spot on the bulb and cause bulb failure. If you do touch the bulb clean the bulb with isopropyl alcohol. 1.

  • Page 110: Off-Season Storage

    Fog engine with Polaris Fogging Oil (aerosol type) according to directions on can. Fuel System Treat the fuel system with Polaris Carbon Clean. If Polaris Carbon Clean is not used, fuel tank, fuel lines, and carburetor should be completely drained of gasoline.
  • Page 111 Engine/Cooling/Exhaust CHAPTER 3 Engine/Cooling/Exhaust ENGINE SPECIFICATIONS ..........3.3 FASTENER TORQUE GUIDE.
  • Page 112 Engine/Cooling/Exhaust COOLING SYSTEM ........... . 3.41 THERMOSTAT REPLACEMENT .

  • Page 113: Engine Specifications

    Engine/Cooling/Exhaust ENGINE SPECIFICATIONS Fastener Torque Guide -2/4 COMPONENT ASSEMBLY NOTES Spark Plug 18-21.6 (24-30) Apply anti-seize to threads. Head Cover 23-27 (31.2-36.6) Throttle Body Hose 7 (9.5) Apply pipe sealant to threads.  Plug-OR- 15.5-20 (21-27.8) Bypass Nozzle 18 (24) Apply pipe sealant to threads.

  • Page 114: Component Torque Sequences

    Engine/Cooling/Exhaust Component Torque Sequences CFI Recoil Cover Cylinder Head Torque Pattern Cylinder Head Torque Pattern (Monoblock) CFI Water Pump Cover CFI Crankcase Torque Pattern Cylinder Torque Pattern Cylinder Torque Pattern (Monoblock)

  • Page 115: Engine Specifications

    Engine/Cooling/Exhaust Engine Specifications PISTON INSTALLED HEAD PISTON RING END TRIGGER ENGINE MODEL HEAD SQUISH CYLINDER VOLUME FLYWHEEL GAP NUMBER INCHES CLEARANCE INCHES INCHES INCHES .014-.020 S4202-6044-OP6N (0.356-0.508) S4357-6044-OL6N .0033-.0054 .045-.058 25.65 - 27.15 (0.085-0.137) S4215-6044-OO6N (1.143-1.482) SVC. Limit=.009" S4316-6044-OL6G S4452-6044-OL6G S4139-8044-OO8G S4229-8044-OO8G .004-.0055...

  • Page 116: Vehicle/Engine Matrix

    Engine/Cooling/Exhaust Vehicle/Engine Matrix MODEL YEAR VEHICLE ENGINE MODEL NUMBER 2010 600 Rush S4202-6044-OP6N 600 Rush/Rush LX/Rush Pro-R S4215-6044-OO6N 800 Rush/Rush LX/Rush Pro-R S4139-8044-OO8G 800 Switchback 1.3/2.0 2011 S4229-8044-OO8G 800 RMK 155 800 RMK Assault S4092-8044-OO8G 800 PRO RMK 155/163 600 Rush/Rush Pro-R/600 Switchback/Adventure/Switchback Pro-R S4357-6044-OL6N 800 Rush/Rush Pro-R/Pro-R LE/800 Switchback/Switchback Pro-R S4360-8044-OL8G...

  • Page 117: Special Tools

    75 - 100mm Micrometer etc. VES threaded stud/cap Use to clamp VES threaded stud/ PS-50753 tool. cap in bench vise. NOTE: Polaris dealers can order the tools listed above through the SPX Service Tools catalog or by calling SPX @ 1-800-328-6657.

  • Page 118: Cylinder Measurement

    Engine/Cooling/Exhaust Cylinder Measurement Inspect cylinder for wear, scratches, or damage. If no damage is evident, measure the cylinder for taper and out of round with a dial bore gauge. Measure the bore 20mm from the top of the cylinder; in line with the piston pin and 90°...

  • Page 119: Piston Inspection

    Engine/Cooling/Exhaust Piston Inspection Piston Ring Installed Gap Check piston for scoring or cracks in piston crown or pin area. Excessive carbon buildup below the ring lands is an indication of piston, ring or cylinder wear. Using only a micrometer, measure the piston outside diameter at a 90°...

  • Page 120: Reed Valve Inspection

    Engine/Cooling/Exhaust Reed Valve Inspection Bearing Fit 1. Loosen the hose clamps. Any time crankshaft bearing failure occurs and the case is reused, check the bearing fit into the case halves using the 2. Remove the throttle body from the intake boots. following procedure.

  • Page 121: Crankshaft Runout Inspection

    Main Bearing = In. / mm. Clean crankshaft thoroughly and oil main and connecting rod bearings with Polaris engine oil. Carefully check each Connecting Rod Side Clearance:  main bearing on the crankshaft. .0114"-.0295" (0.289-0.749mm) Due to extremely close tolerances, the bearings must be Maximum Clearance Differential...

  • Page 122: Piston Needle Bearing

    Engine/Cooling/Exhaust Piston Needle Bearing 1. Clean the end of the connecting rod and inspect inner bore with a magnifying glass. Look for any surface irregularities including pitting, wear, or dents. 2. Run a fingernail around the inside of the rod and check for rough spots, galling, or wear.

  • Page 123: Crankshaft Index

    3. With a section of wire (wire coat hanger), anchor it to a convenient spot. Bend one end at the outer Polaris crankshafts are pressed together. The connecting perimeter of the degree wheel as shown below. rod journal center lines are indexed 180° apart from each 4.

  • Page 124: Cylinder Honing

    (transfer port area). Use electrical contact cleaner if necessary to clean these areas. Rinse thoroughly, dry with compressed air, and oil the bore immediately with Polaris Premium 2 Cycle Lubricant. EXAMPLE OF A CROSS HATCH PATTERN NOTE: Always check piston to cylinder clearance and piston ring installed gap after honing is complete.

  • Page 125: Crankshaft Truing

    Engine/Cooling/Exhaust Crankshaft Truing illustrations below. Use Crankshaft alignment kit PN 2870569. Lubricate the bearings and clamp the crankshaft securely in the holding fixture. If truing the crankshaft requires NOTE: The rod pin position in relation to the dial striking with a hammer, always be sure to re-check indicator tells you what action is required to previously straightened areas to verify truing.

  • Page 126: Engine Mounting Systems

    Engine/Cooling/Exhaust ENGINE MOUNTING SYSTEMS 2010 600 Engine Mounting ENGINE ASSEMBLY TORQUE LINK INNER BRACKET TORQUE LINK TORQUE LINK OUTER BRACKET TORQUE LINK MOUNT RADIAL INSERT (LARGE) MOUNT BRACKET MOUNT ENGINE MOUNTS MOUNT BRACKET MOUNT W/CLINCH NUT MOUNT RADIAL INSERT (SMALL) RADIAL INSERT (SMALL) NOTE: SEE ENGINE MOUNT BOLT SERVICE REPLACEMENT KIT MOUNT W/CLINCH NUT...
  • Page 127 Engine/Cooling/Exhaust 2011 600 Engine Mounting TORQUE LINK INNER BRACKET ENGINE ASSEMBLY TORQUE LINK OUTER BRACKET TORQUE LINK E(NO Loctite®) TORQUE LINK MOUNT RADIAL INSERT (LARGE) MOUNT BRACKET MOUNT ENGINE MOUNTS MOUNT BRACKET MOUNT W/CLINCH NUT RADIAL INSERT(SMALL) MOUNT RADIAL INSERT(SMALL) MOUNT W/CLINCH NUT NOTE: SEE ENGINE MOUNT BOLT SERVICE REPLACEMENT KIT Assembly Notes:...

  • Page 128: 2011 800 Engine Mounting

    Engine/Cooling/Exhaust 2011 800 Engine Mounting ENGINE ASSEMBLY TORQUE LINK INNER BRACKET TORQUE LINK OUTER BRACKET TORQUE LINK E(NO Loctite®) TORQUE LINK MOUNT RADIAL INSERT (LARGE) MOUNT BRACKET MOUNT RADIAL INSERT (LARGE) ENGINE MOUNTS MOUNT BRACKET MOUNT W/CLINCH NUT RADIAL INSERT (LARGE) MOUNT RADIAL INSERT (SMALL) MOUNT W/CLINCH NUT (PTO-SMALL)
  • Page 129 Engine/Cooling/Exhaust 2012-2013 600/800 Engine Mounting ENGINE ASSEMBLY TORQUE LINK INNER BRACKET TORQUE LINK OUTER BRACKET TORQUE LINK E(NO Loctite®) TORQUE LINK MOUNT RADIAL INSERT (LARGE) MOUNT BRACKET MOUNT RADIAL INSERT (LARGE) ENGINE MOUNTS MOUNT BRACKET MOUNT W/CLINCH NUT RADIAL INSERT (LARGE) MOUNT RADIAL INSERT (SMALL) MOUNT W/CLINCH NUT (PTO-SMALL)

  • Page 130: Engine Mount Bolt Service Replacement Kit

    Engine Mount Screw Installation PN 2204633 1. Determine which bolt(s) is going to be installed. The engine mount bolt replacement kit includes the NOTE: Polaris recommends installing the Engine following parts: Mount Bolt Replacement Kit (PN 2204633) if original 2010-2011 bolts are installed.

  • Page 131: Recoil Assembly

    Engine/Cooling/Exhaust RECOIL ASSEMBLY Rope Removal and Installation RECOIL HUB SCREWS TAB (ENGAGES INSIDE PULLEY) FRICTION SPRING ROPE SCREW HANDLE FRICTION PLATE RATCHET GUIDE ROPE GUIDE (HOLE) RATCHET COVER REEL RETURN SPRING BUSHING SCREWS RECOIL SPRING TAB (ENGAGES INSIDE HOUSING) grease. 7.

  • Page 132: Engine Component Assemblies

    Engine/Cooling/Exhaust ENGINE COMPONENT ASSEMBLIES 600 Cylinder Head/Cylinders/Pistons BLEED SCREW THERMOSTAT COVER HEAD COVER O-RINGS THERMOSTAT O-RINGS GASKET KNOCK SENSOR CYLINDERS TEMP. SENSOR BASE GASKETS CYLINDER HEAD PISTON RINGS PISTON BEARING PISTON PIN C-CLIP Piston Matrix Engine Model Piston PN Piston ID A: 70 in-lbs (8 Nm)...
  • Page 133 13. The assembly process is the reverse of disassembly. 14. Always use new gaskets and o-rings during assembly. Liberally coat the inside of each cylinder and the outside of each piston with Polaris two-stroke engine oil. 15. Always refresh the cylinder crosshatch pattern using a 320 grit stone.

  • Page 134: 600/800 Recoil/Stator Assembly

    Engine/Cooling/Exhaust 600/800 Recoil/Stator Assembly TRIGGER COILS FLYWHEEL NUT STATOR FLYWHEEL RECOIL HOUSING A: 9 ft-lbs (12 Nm) B: 5 ft-lbs (7 Nm) (Trigger coil fasteners) C: 90 ft-lbs (122 Nm) - Apply Loctite® 242™ (Do not use an impact wrench to remove or install flywheel nut.)...
  • Page 135 Engine/Cooling/Exhaust Disassembly / Assembly Process 1. Remove the exhaust pipe and silencer. 2. If the recoil assembly does not require attention, the recoil rope can remain attached to the handle. If recoil component work is desired, reference the Recoil Assembly section. 3.

  • Page 136: 600 Crankcase/Crankshaft Assembly

    Engine/Cooling/Exhaust 600 Crankcase/Crankshaft Assembly GEAR CLAMPS CYLINDER STUDS INTAKE BOOT ALIGNMENT DOWELS REED STUFFERS REED BLOCKS TRIGGER COIL WIRE RETAINER OIL INJECTION CHECK VALVE QTY. 5 PTO SEAL NEEDLE BEARINGS FLYWHEEL KEY PTO BEARINGS MAG BEARING CRANKSHAFT MAG SEAL TRIGGER COIL WIRE RETAINER DO NOT FILL MAG STATOR WIRE HARNESS RETAINER BEARING OIL...

  • Page 137: 600 Dc-Cfi-2 Crankshaft Identification

    12. Liberally coat crankshaft bearings components with Polaris two-stroke engine oil. 600 DC-CFI-2 Crankshaft Identification 4. Remove all crankcase fasteners except ones marked 5-6-7-8 indicated below. Loosen these 4 bolts to Two different crankshaft assemblies (Type 1 and Type 2) reveal about a 1/6"-1/8"...

  • Page 138: Dc-Cfi-2 Cylinder Head/Cylinder/Pistons

    Engine/Cooling/Exhaust 800 DC-CFI-2 Cylinder Head/Cylinder/ Pistons BLEED SCREW THERMOSTAT COVER THERMOSTAT GASKET SPARK PLUGS HEAD COVER TEMP. SENSOR CYLINDER O-RINGS THROTTLE BODY HOSE CYLINDER HEAD PLUG* BASE GASKET BYPASS NOZZLE* O-RINGS KNOCK SENSOR PISTON RINGS PISTON PIN PISTON C-CLIP * = SEE PLUG / BYPASS MATRIX A: 70 in-lbs (8 Nm)...

  • Page 139: Cylinder Head/Cylinder/Piston Notes

    15. Always use new gaskets and o-rings during Engine Model Plug Bypass Nozzle assembly. Liberally coat the inside of each cylinder bore and the outside of each piston with Polaris two- S4139-8044-OO8G stroke engine oil. S4229-8044-OO8G S4360-8044-OL8G 16. Always refresh the cylinder crosshatch pattern using S4361-8044-OL8G...

  • Page 140: 800 Dc-Cfi-2 Crankcase/Crankshaft

    Engine/Cooling/Exhaust 800 DC-CFI-2 Crankcase/Crankshaft GEAR CLAMPS REED STUFFERS ALIGNMENT DOWELS ALIGNMENT DOWELS ADAPTER PLATE SEAL GUARD PTO SEAL REED BLOCKS STATOR WIRE RETAINER OIL INJECTION CHECK VALVE QTY. 5 WRIST PIN BEARINGS PTO BEARING FLYWHEEL KEY MAG BEARING MAG SEAL STATOR WIRE RETAINER A: 9 ft-lbs (12 Nm)...

  • Page 141: 800 Dc-Cfi-2 Crankshaft Identification

    11. Liberally coat crankshaft bearings components with Polaris two-stroke engine oil. 3. Remove all crankcase fasteners except ones marked 5-6-7-8 indicated below. Loosen these 4 bolts to 800 DC-CFI-2 Crankshaft Identification reveal about a 1/6"-1/8" bolt gap. Two different crankshaft assemblies (Type 1 and Type 2) are used for production and service parts.

  • Page 142: 600/800 Dc-Cfi Water And Oil Pump Assembly

    Engine/Cooling/Exhaust 600/800 DC-CFI Water and Oil Pump Assembly BEARING SEAL CROSS SHAFT WASHER OIL PUMP WASHER MECHANICAL SEAL WASHER IMPELLER WASTER PUMP COVER GASKET O-RING WASTER PUMP COVER A: 9 ft-lbs (12 Nm) B: 9 ft-lbs (12 Nm) C: 18 ft-lbs (Nm) Apply pipe sealant. Oil Pump Bleed Screw: 2.2 ft-lbs (3 Nm) Water / Oil Pump Crossshaft Axial End Play .009"...
  • Page 143 Engine/Cooling/Exhaust Disassembly / Assembly Process IMPORTANT: Use the mechanical seal installation tool to install the water pump seal, PN: 2872010. 1. Remove the coolant from the engine using a siphon, wet/dry vac. or a drain pan. 2. Remove the oil tank/clutch cover assembly, airbox, exhaust pipe and resonator.

  • Page 144: Oil Hose Routing

    Engine/Cooling/Exhaust Oil Hose Routing TEE FITTING 3.34...

  • Page 145: Engine Removal

    NOTE: Inspect all parts for wear or damage during the motor bracket. Remove the worm drive shaft from disassembly. Replace all seals, o-rings, and gaskets the case-mounted drive gear. with Genuine Pure Polaris parts during assembly.   MOUNTING NUT Torx screws are used throughout the engine compartment.
  • Page 146 Engine/Cooling/Exhaust 7. Remove the upper steering drag link from the lower 12. Remove the coolant return hoses from the water steering shaft. pump cover. 8. Remove the airbox assembly.See “Air Box Servicing” 13. Disconnect the throttle cable from the throttle body. on page 2.24.
  • Page 147 Engine/Cooling/Exhaust 16. Remove the exhaust y-pipe from the engine using a 19. Remove the two engine mount screws from the MAG- ball-end Allen wrench. Remove the exhaust gaskets. side of the engine. If un-damaged, they can be re-used during assembly. NOTE: Use a six to eight inch extended Allen wrench to access the MAG-side engine mounting bolts.

  • Page 148: Engine Installation

    Engine/Cooling/Exhaust Engine Installation 12. Reinstall the exhaust gaskets and y-pipe. Torque y- pipe fasteners to specification. 1. Clean the engine compartment. 2. Inspect engine mounts for damage. Replace mounts or radial inserts at this time. If any mount bracket was removed, reinstall and torque screws to specification.
  • Page 149 Engine/Cooling/Exhaust 16. Reinstall the steering drag link with the rod ends NOTE: Install the silencer mount rubber dampener parallel to each mating surface. Torque nuts to with the fat end facing outwards. specification. Steering Drag Link Rod End Nuts: 37 ft-lbs (50 Nm) SILENCER MOUNT 17.
  • Page 150 2.24. 26. Reinstall the clutch cover/oil tank assembly. See “Oil Tank/Clutch Cover Service” on page 2.14. 27. Fill the coolant surge tank with 60/40 Polaris engine coolant. Follow the Cooling System Fill/Bleed Procedure outlined in Chapter Two. See “Cooling System Bleeding”...

  • Page 151: Cooling System

    Engine/Cooling/Exhaust COOLING SYSTEM 5. Verify the bleed screw and washer are installed. Thermostat Orientation Thermostat Replacement The thermostat must be installed in the cylinder head as BLEED SCREW shown in the illustrations. WASHER Center Thermostat Location BRIDGE ALIGNED WITH HOLES HOUSING COVER Offset Thermostat Location THERMOSTAT...

  • Page 152: 2010 600 Rush Cooling System

    Engine/Cooling/Exhaust 2010 600 RUSH Cooling System SURGE BOTTLE HOSE (BYPASS-TO-SURGE TANK) REAR TUNNEL COOLER HOSE (THROTTLE BODY-TO-SURGE TANK) HOSE (SURGE TANK-TO-WATER PUMP) FRONT TUNNEL COOLER HOSE (TEE-TO-HEAT EXCHANGER) WATER PUMP COVER BARBED NOZZLE HEAT EXCHANGER BYPASS CIRCUIT ONLY ACTIVE WHEN THERMOSTAT IS CLOSED FRONT EXCHANGER, FRONT TUNNEL COOLER, AND REAR TUNNEL COOLER CIRCUITS ACTIVE WHEN THERMOSTAT IS OPEN NOTE: When the thermostat is closed, engine coolant is bypassed back to the surge bottle....
  • Page 153 Engine/Cooling/Exhaust 2011 600 RUSH Cooling System MID FLAP COOLER SURGE BOTTLE HOSE (BYPASS-TO-SURGE TANK) REAR TUNNEL COOLER HOSE (THROTTLE BODY-TO-SURGE TANK) HOSE (SURGE TANK-TO-WATER PUMP) FRONT TUNNEL COOLER HOSE (TEE-TO-HEAT EXCHANGER) WATER PUMP COVER BARBED NOZZLE HEAT EXCHANGER BYPASS CIRCUIT ONLY ACTIVE WHEN THERMOSTAT IS CLOSED FRONT EXCHANGER, FRONT TUNNEL COOLER, AND REAR TUNNEL COOLER CIRCUITS ACTIVE WHEN THERMOSTAT IS OPEN NOTE: When the thermostat is closed, engine coolant is bypassed back to the surge bottle....
  • Page 154 Engine/Cooling/Exhaust 2011 800 RUSH Cooling System MID FLAP COOLER SURGE BOTTLE HOSE (THROTTLE BODY-TO-SURGE TANK) REAR TUNNEL COOLER HOSE (SURGE TANK-TO-WATER PUMP) FRONT TUNNEL COOLER HOSE (THERMOSTAT OUTLET-TO REAR COOLERS) HOSE (CYLINDER BYPASS -TO-HEAT EXCHANGER) WATER PUMP COVER BARBED NOZZLE HEAT EXCHANGER NOTE: Front heat exchanger circuit always active.

  • Page 155: 2012-2013 600 Rush/Switchback Cooling System

    Engine/Cooling/Exhaust 2012-2013 600 RUSH/Switchback Cooling System MID FLAP COOLER SURGE BOTTLE HOSE (BYPASS-TO-SURGE TANK) WEAR STRIPCOOLERS HOSE (THROTTLE BODY-TO-SURGE TANK) HOSE (SURGE TANK-TO-WATER PUMP) FRONT TUNNEL COOLER HOSE (TEE-TO-HEAT EXCHANGER) WATER PUMP COVER BARBED NOZZLE HEAT EXCHANGER BYPASS CIRCUIT ONLY ACTIVE WHEN THERMOSTAT IS CLOSED FRONT EXCHANGER, FRONT TUNNEL COOLER, AND REAR TUNNEL COOLER CIRCUITS ACTIVE WHEN THERMOSTAT IS OPEN NOTE: When the thermostat is closed, engine coolant is bypassed back to the surge bottle....
  • Page 156 Engine/Cooling/Exhaust 2012-2013 800 RUSH/Switchback Cooling System MID FLAP COOLER HOSE (THROTTLE BODY-TO-SURGE TANK) SURGE BOTTLE HOSE (SURGE TANK-TO-WATER PUMP) REAR TUNNEL COOLER HOSE (THERMOSTAT OUTLET-TO REAR COOLERS) HOSE (CYLINDER BYPASS FRONT TUNNEL COOLER -TO-HEAT EXCHANGER) WATER PUMP COVER BARBED NOZZLE HEAT EXCHANGER NOTE: Front heat exchanger circuit always active.

  • Page 157: Switchback Assault/Base Rmk Cooling System

    Engine/Cooling/Exhaust Switchback Assault/Base RMK Cooling System HOSE (FRONT COOLER TO-SURGE TANK) SURGE BOTTLE HOSE (THROTTLE BODY -TO-SURGE TANK) HOSE (THERMOSTAT OUTLET-TO REAR COOLERS) REAR TUNNEL COOLER HOSE (SURGE TANK -TO-WATER PUMP) HOSE (HEAD BYPASS-TO FRONT TUNNEL COOLER) HOSE (SURGE TANK-TO-WATER PUMP) NOTE: Front tunnel cooler circuit always active.

  • Page 158: Pro Rmk/Rmk Assault Cooling System

    Engine/Cooling/Exhaust PRO RMK/RMK Assault Cooling System SURGE BOTTLE HOSE (THROTTLE BODY-TO-SURGE TANK) HOSE (THERMOSTAT OUT-TO-TUNNEL COOLERS) HOSE (SURGE TANK-TO-WATER PUMP) NOTE: Models feature 3.5mm thermostat bleed hole. Cylinder head outlet plugged.  Thermostat opening temperature is 120° F (49° C). 3.48...

  • Page 159: 600 Indy Cooling System

    Engine/Cooling/Exhaust 600 INDY Cooling System HOSE (FRONT COOLER-TO-SURGE TANK) HOSE (THROTTLE BODY-TO-SURGE TANK) SURGE BOTTLE HOSE (THERMOSTAT OUT-TO-TUNNEL COOLERS) HOSE (BOTTLE TO WATER PUMP) HOSE (TO FRONT COOLER - ALWAYS ACTIVE) FRONT TUNNEL COOLER NOTE: Models feature 2mm thermostat bleed hole. Front tunnel cooler always active. ...

  • Page 160: Front Heat Exchanger Service

    Engine/Cooling/Exhaust Front Heat Exchanger Service 8. Remove the bottom heat exchanger fastener. 1. Remove the left and right door panels. Remove the hood assembly. 2. Remove the exhaust pipe. BOTTOM FASTENER 3. Drill out and remove the rivets that attach the air dam plate to the bulkhead, and the two rivets that attach the nosepan to the plate.

  • Page 161: Exhaust Systems

    Engine/Cooling/Exhaust EXHAUST SYSTEMS PRO-RIDE DC-CFI-4 Exhaust System HEAT SHIELD ZINC-PLATED (YELLOW) SPRINGS HEAT SHIELD MOUNT BUMPER (INSTALL LARGE END TO OUTSIDE) GASKET EXHAUST SEAL EXHAUST PIPE GASKETS STAINLESS STEEL (GRAY) SPRINGS When removing the exhaust pipe, disconnect the EGT probe wire harness. Do not remove the EGT probe from the pipe if not necessary.

  • Page 162: Pro-Ride Dc-Cfi-2 Exhaust System

    Engine/Cooling/Exhaust PRO-RIDE DC-CFI-2 Exhaust System ZINC-PLATED (YELLOW) SPRINGS ZINC-PLATED (YELLOW) SPRINGS ISOLATOR GASKET ZINC-PLATED (YELLOW) SPRINGS CHASSIS GROMMET GASKET EXHAUST PIPE EXHAUST SEAL STAINLESS STEEL (GRAY) SPRINGS ZINC-PLATED (YELLOW) SPRINGS A: EGT Sensor: 32 ft-lbs (44 Nm) Apply anti-seize to threads....

  • Page 163: Variable Exhaust System (Ves)-Threaded Valve

    Engine/Cooling/Exhaust Variable Exhaust System (VES)-Threaded Valve SPACER CAP NUT GUILLOTINE EV CAP GASKET EV BASE SPRING BELLOWS EV Cap Screws (A): 10.5-13.5 ft-lbs (14.3-18.3 Nm) Apply Loctite® 242™ to cylinder screws. Cap Nut (B): 14-18 ft-lbs (19.1-24.5 Nm) Apply Loctite® 242™ to threads. Assembly Notes: •...

  • Page 164: Variable Exhaust System (Ves)-Threaded Stud

    Engine/Cooling/Exhaust Variable Exhaust System (VES)-Threaded Stud BELLOWS EV BASE SPRING GUILLOTINE EV CAP CAP NUT THREADED STUD/WASHER GASKET soft-faced bench vise. Loosen cap nut. EV Cap Screws(A): 10.5-13.5 ft-lbs (14.3-18.3 Nm) Apply Loctite® 242™ to cylinder screws. Cap Nut/Threaded Stud Asm.(B): 18-22 ft-lbs (24.5-29.9 Nm) Apply Loctite®...
  • Page 165 Cleanfire Fuel Injection CHAPTER 4 Cleanfire Fuel Injection SERVICE WARNINGS AND PRECAUTIONS ........4.3 SERVICE WARNINGS .
  • Page 166 Cleanfire Fuel Injection DIGITAL WRENCH® DIAGNOSTIC SOFTWARE ......4.34 DIGITAL WRENCH® DIAGNOSTIC SOFTWARE OVERVIEW....4.34 SPECIAL TOOLS .

  • Page 167: Service Warnings And Precautions

    Cleanfire Fuel Injection SERVICE WARNINGS AND WARNING PRECAUTIONS Service Warnings * Gasoline is extremely flammable and explosive under certain conditions. When servicing the fuel system, it is * EFI components are under high pressure. Verify important to heed the following warnings. system pressure has been relieved before disassembly.

  • Page 168: Engine Protection Features

    Cleanfire Fuel Injection ENGINE PROTECTION FEATURES Engine Overheating Troubleshooting If the hot lamp is illuminated or flashing with the engine Engine Temperature RPM Limit overheat RPM misfire enabled, reference the table below. The ECU will illuminate the instrument cluster engine hot LED when it determines the engine is overheating.

  • Page 169: Detonation Protection (Det)/Rpm Limit

    Cleanfire Fuel Injection Detonation Protection (DET)/RPM Limit NOTE: A DET Troubleshooting flowchart is located at the end of the chapter. When DET is sensing and taking action to reduce detonation, the driver may notice a drop in engine RPM CAUSE OF DET ACTIVATION SOLUTION and/or reduced performance.

  • Page 170: System Overview

    / rectifier. • Capacitor: The capacitor suppresses voltage • Diagnostic Connector: The ECU can spikes and ensures consistent voltage throughout communicate with the Polaris Digital Wrench® the DC-CFI (RED-RED/WHT) circuits. software and can be re-flashed, monitored and will display trouble codes.

  • Page 171: Fuel Select Feature

    Cleanfire Fuel Injection Fuel Select Feature <91/10% ETHANOL/24 OHM Resistor Plug Part Number =2411280 (Installed at the factory.) CAUTION Lock Screw Always verify the ETHANOL resistor plug is installed in the selector plug if unsure of fuel type. Severe engine damage may occur if the PREMIUM resistor plug is installed when using ethanol-blended fuel.

  • Page 172: Instrument Cluster Fuel Selector

    Cleanfire Fuel Injection Instrument Cluster Fuel Selector Digital Instrument Cluster: 1. Start the engine. CAUTION 2. Lock the parking brake. 3. Press and release the “SEL” button on the gauge or the “SET” button on the left hand control until either Always verify ETHANOL is selected on the instrument “Eth”...

  • Page 173: Diagnostic Trouble Codes (Dtcs)

    Cleanfire Fuel Injection Diagnostic Trouble Codes (DTCs) TROUBLE CODE DESCRIPTION CODE Throttle Position Sensor Abnormal Rate of P0120 TPS signal changes too rapidly to be correct. Change Throttle Position Sensor Voltage High P0123 TPS signal is above 4.39 VDC. Throttle Position Sensor Voltage Low P0122 TPS signal is below 0.7 VDC.
  • Page 174 Cleanfire Fuel Injection TROUBLE CODE DESCRIPTION CODE OPEN circuit or short to ground. Can be P0264 caused by faulty wiring, injector, stator or Port PTO Injector Circuit ECU. P0265 Circuit shorted to battery voltage. Engine speed is above 6000 RPM and the Detonation Sensor Circuit Voltage Low P0327 sensor signal is above 4.3 VDC for at least 2...

  • Page 175: Diagnostic Trouble Code (Dtc) Troubleshooting

    Cleanfire Fuel Injection Diagnostic Trouble Code (DTC) Troubleshooting Always use the Digital Wrench® diagnostic software program to troubleshoot DTCs, and overall performance problems. Digital Wrench® can be used to display trouble codes and offers guided diagnostics. Guided diagnostics allows the technician to perform diagnostic checks to isolate the root problem.

  • Page 176: Analog/Digital Ic Error Code Display

    Cleanfire Fuel Injection Analog/Digital IC Error Code Display Digital IC Error Code Display Active diagnostic trouble codes can be reviewed by Active diagnostic trouble codes can be reviewed by accessing the instrument cluster’s diagnostic display accessing the instrument cluster’s diagnostic display mode.

  • Page 177: Ecu 34 Pin Connector (Chassis)

    Cleanfire Fuel Injection ECU 34 Pin Connector (Chassis) NOTE: Wire Entry View COLOR GOES TO CONNECTOR FUNCTION DG/WHT IGNITION SWITCH STARTER LOCKOUT RD/BLK ELECTRIC START BATTERY VOLTAGE BLK/DB SENSOR GROUND SPLICE SENSOR GROUND DG/RD GROUND SPEED SPLICE GROUND SPEED SIGNAL BLACK IGNITION SWITCH HARD STOP SWITCH...

  • Page 178: Ecu 26 Pin Connector (Engine)

    Cleanfire Fuel Injection ECU 26 Pin Connector (Engine) NOTE: Wire Entry View COLOR GOES TO CONNECTOR FUNCTION PTO CRANKCASE INJECTOR DRIVER DARK BLUE (DC-CFI-4) FUEL INJECTOR HARNESS PLUG DARK BLUE/WHT PTO CYLINDER INJECTOR DRIVER RED/DARK BLUE FUEL INJECTOR POWER SUPPLY (16 VDC) DARK GREEN 5 TOOTH CPS SENSOR SENSOR SIGNAL...

  • Page 179: Exhaust Temperature Sensor

    Cleanfire Fuel Injection Exhaust Temperature Sensor Crankshaft Position Sensors (CPS) The 5 tooth crank position sensor picks up all 5 flywheel teeth and determines the following: • Judge direction of rotation (forward and backward) • Ignition advance angle control • Injector drive angle control Sensor Specifications •...

  • Page 180: Exhaust Valve Solenoid

    Cleanfire Fuel Injection Exhaust Valve Solenoid 2. Insert the blade of a .030" feeler gauge between the rib and sensor face. If there is no drag felt on the feeler gauge, the CPS must be adjusted. 3. To adjust a CPS, use an 8 inch pry bar to carefully deflect the sensor.

  • Page 181: Engine Coolant Temperature Sensor

    Cleanfire Fuel Injection Engine Coolant Temperature Sensor Throttle Body Removal Sensor Specifications 1. Remove the oil tank/clutch cover assembly. Operating Temperature -22°F - +248 °F 2. Remove the airbox assembly. Range (-30°C - 120°C) 3. Pinch off the coolant lines with the hose pincher tool PN PU-45149.

  • Page 182: Dc-Cfi-4 Fuel Injectors/Fuel Rail

    Cleanfire Fuel Injection DC-CFI-4 FUEL INJECTORS/FUEL Fuel Pressure Gauge (PU-43506-A) RAIL PU-43506-A CONNECT TO ADAPTER Fuel Injectors Fuel Pressure Gauge Adapters OEM PART NUMBER Specifications Resistance 12@ 68°F (20°C) Fuel Rail Bleeding / Pressure Testing All CFI engine fuel return hoses feature an inline Schrader valve that can be used to bleed the fuel system pressure and observe fuel system pressure when using the fuel pressure gauge and specified adapter.

  • Page 183: Disconnect Fittings

    Cleanfire Fuel Injection Fuel Rail/Injector Removal/Installation 5. To bleed the fuel system pressure after the engine is stopped, place the tool’s bleed hose into an appropriate fuel handling container. Open the valve to NOTE: Leave protective caps installed until release the pressure and drain residual fuel. instructed to remove.
  • Page 184 Cleanfire Fuel Injection 6. Measure from the end of the injector (as shown below)  2. Remove the panduit straps as shown. 3" (76.2mm) and cut the injector off. 3” (76.2mm) 7. Strip the harness end injector wire covering .25" - .375"...
  • Page 185 Cleanfire Fuel Injection 14. Replace the harness to the original routing and apply panduit straps back to the original locations. NOTE: Refer to Step 2 for proper routing and strap location. 15. Install the engine if it was removed. 16. If different color injectors were installed, re-flash the ECU to the new color code.

  • Page 186: Fuel System Assembly

    Cleanfire Fuel Injection Fuel System Assembly RETURN HOSE w/SCHRADER VALVE SUPPLY HOSE w/FILTER FILTER BRACKET P-CLAMP (INSTALLED UNDER FILTER BRACKET) CYLINDER (PORT) INJECTORS CRANKCASE INJECTORS THROTTLE POSITION SENSOR (TPS) A: 9 ft-lbs (12 Nm) B: 1.5 ft-lbs (2 Nm) Position p-clamp behind bracket. 4.22...

  • Page 187: Dc-Cfi-2 Fuel Injectors/Fuel Rail

    Cleanfire Fuel Injection DC-CFI-2 FUEL INJECTORS/FUEL NOTE: In addition to the fuel injector o-rings, an RAIL isolator o-ring (2011) or bushing is installed inside each cylinder fuel injector bore. Fuel Injectors/Assembly To obtain the correct fuel injector set for the vehicle, always reference the model-specific parts manual when DC-CFI-2 engines feature a dual fuel injector/wiring ordering a new fuel injector set.

  • Page 188: Fuel Rail Bleeding / Pressure Testing

    Cleanfire Fuel Injection Fuel Rail Bleeding / Pressure Testing Fuel Pressure Gauge Adapters (PFA with Schrader Valve) Some models feature a Schrader valve located on the pump flange assembly (PFA) that can be used to bleed or test the fuel system pressure when using the fuel pressure gauge and specified adapter.

  • Page 189: Disconnect Fittings

    Cleanfire Fuel Injection NOTE: Observe pressure reading at idle and while 3. Reconnect the fuel hoses by coating each hose end operating the vehicle. with a light film of two stroke engine oil. 4. Carefully install the male end of the hose into the center of the female housing.

  • Page 190: Fuel Rail Microdampers

    Cleanfire Fuel Injection Fuel Rail Microdampers The DC-CFI-2 fuel rail assembly contains two fuel pressure microdampers. The microdampers suppress fuel pressure pulses that occur when each fuel injector is activated. The microdampers are considered “life of engine” components and servicing is not recommended. If a microdamper is removed, apply a light film of two-stroke engine oil to the o-ring during installation.

  • Page 191: Fuel Rail/Injector Removal And Installation

    Cleanfire Fuel Injection Fuel Rail/Injector Removal and Installation FUEL INJECTOR ASM. FUEL RETURN FUEL SUPPLY 2011-ISOLATOR O-RING 2012-2013-GREEN BUSHING FUEL RAIL ASSEMBLY 8. Carefully pull the rail away from the engine and injectors. Remove the injectors from the cylinder. NOTE: Always use new o-rings/isolators after fuel A: 9 ft-lbs (12 Nm)...

  • Page 192: Fuel Tank/Pump Service

    Cleanfire Fuel Injection FUEL TANK/PUMP SERVICE 2010 Fuel Tank/Pump Assembly SEAT MOUNT BRACKET VENT/VAC HOSE FUEL TANK BRACKET FUEL TANK PFA NUT PFA GASKET PUMP ASSEMBLY A: 10 ft-lbs (14 Nm) B: 6 ft-lbs (8 Nm) C: 28 ft-lbs (38 Nm) D: 7 ft-lbs (10 Nm) SERVICE PARTS: •...

  • Page 193: 2011-2013 Rush/Switchback Fuel Tank/Pump Assembly

    Cleanfire Fuel Injection 2011-2013 RUSH/Switchback Fuel Tank/ Pump Assembly SEAT MOUNT BRACKET WASHER VENT/VAC HOSE FUEL TANK BRACKET FUEL TANK PFA NUT PFA GASKET PUMP ASSEMBLY A: 10 ft-lbs (14 Nm) B: 6 ft-lbs (8 Nm) C: 28 ft-lbs (38 Nm) D: 7 ft-lbs (10 Nm) SERVICE PARTS: •...

  • Page 194: 2011-2013 Indy/Switchback Assault/Rmk Fuel Tank/Pump Assembly

    Cleanfire Fuel Injection 2011-2013 INDY/Switchback Assault/RMK Fuel Tank/Pump Assembly SEAT MOUNT BRACKET FUEL TANK VENT/VAC HOSE PFA NUT PFA GASKET PICKUP ASSEMBLY PUMP ASSEMBLY A: 10 ft-lbs (14 Nm) B: 6 ft-lbs (8 Nm) C: 28 ft-lbs (38 Nm) D: 7 ft-lbs (10 Nm) SERVICE PARTS: •...

  • Page 195: Fuel Tank Service

    Cleanfire Fuel Injection Fuel Tank Service 9. Remove the old gasket and discard. CAUTION 1. Remove the tank cap and siphon the fuel in the tank into a suitable container. 2. Remove the seat assembly ALWAYS REPLACE PFA GASKET WITH NEW 3.

  • Page 196: Fuel Pump/Level Sender Test Specifications

    Cleanfire Fuel Injection 15. Using the PFA spanner wrench and nut socket NOTE: Using a hand pump to pressurize the fuel (PS48459), tighten the PFA to specification. tank may take a very long time. The installation of an in-line Schrader Valve (PN: 2872602) and the use of a pressure pump (bicycle...

  • Page 197: Rush/Switchback Fuel Pump Pickup Orientation

    Cleanfire Fuel Injection Rush/Switchback Fuel Pump Pickup Orientation When servicing the Rush fuel pump pickup assembly or troubleshooting an issue with a stuck low fuel gauge display on the MFD gauge, verify the pickup assembly is orientated as shown in the MY11-current Pickup Assembly illustration below.

  • Page 198: Digital Wrench® Diagnostic Software

    Digital Wrench® Diagnostic Software Overview IMPORTANT: Refer to Section 2, 3 and 4 in the Instruction Manual provided in the Digital Wrench® Diagnostic Kit to install the Polaris Digital Wrench® diagnostic software on your computer. The Digital Wrench® diagnostic software allows the •...

  • Page 199: Digital Wrench® Communication Errors

    Digital Wrench® related problem, visit the Digital Wrench® Knowledge Base for the most current troubleshooting information, FAQs, downloads and software updates at: http://polaris.diagsys.com/. ECU POWER 3. Connect the chassis power-up harness to a fully charged 12VDC battery. Connect the chassis power- up harness to the ECU POWER connector.

  • Page 200: Digital Wrench® Serial Number Location

    Cleanfire Fuel Injection NOTE: Connecting the chassis power-up harness to 2. Proceed to http://polaris.diagsys.com to see if a the DC POWER TEST plug will power the DC chassis newer update is available. circuit. CAUTION Do not connect DC power to the AC power test plug. This plug is for testing the AC power circuit with a digital volt/ Digital Wrench®...
  • Page 201 Cleanfire Fuel Injection 5. Click on “Digital Wrench® Version Updates”. should match the update you just downloaded. Digital Wrench® Update IMPORTANT: You must already have the current version installed before adding an update. Updates will not install if you are using an older version loaded on your PC.

  • Page 202: Digital Wrench® Feature Map

    Cleanfire Fuel Injection Digital Wrench® Feature Map 4.38...

  • Page 203: Updating Digital Wrench

    6. Locate and click on the update file. Save the file to the PC or laptop’s desktop. NOTE: Only authorized Polaris dealers distributors can access the dealer Internet website. 1. Log on to www.polarisdealers.com. 2. Locate the “SERVICE AND WARRANTY” drop-down menu.

  • Page 204: Version Identification

    Cleanfire Fuel Injection Version Identification Vehicle History Information 1. Start the Digital Wrench® software. Selecting the Vehicle History Information option displays the following information: 2. Locate the version ID on the title screen. • Throttle Position (TPS) history • Engine RPM history •...

  • Page 205: Ecu Replacement

    Cleanfire Fuel Injection ECU Replacement After completing the ECU replacement procedure, reflash the ECU with the current ECU calibration file for the Use the ECU replacement feature whenever installing a vehicle using the engine controller reprogramming new service ECU on the vehicle. Follow the guided procedure.
  • Page 206 Cleanfire Fuel Injection • CLOSE NON-ESSENTIAL PROGRAMS: Polaris NOTE: New service replacement ECUs recommends that you DO NOT install non- programmed as “no-start” and must be reflashed for essential programs on a Service Department the engine and fuel injector code.
  • Page 207 Cleanfire Fuel Injection 9. Enter the REQUEST CODE generated by Digital 14. Copy the code, and then enter the code into the Wrench® into the information box. AUTHORIZATION box in Digital Wrench®. Click “CONTINUE”. 10. After entering REQUEST CODE, click 15.

  • Page 208: Digital Wrench® Data Grid Screenshots

    Cleanfire Fuel Injection Digital Wrench® Data Grid Screenshots 2010 RUSH 600 - Engine at Idle (75° F shop room temperature/1,060 ft. ASL) The data grid can display numerous sensor/switch inputs and outputs. Not all are shown in the screenshots above. Use the (+) and (-) button to add and remove data parameters.

  • Page 209: Throttle Position Sensor

    Cleanfire Fuel Injection THROTTLE POSITION SENSOR Throttle Position Sensor (TPS) Overview CAUTION The throttle position sensor (TPS) is set at the time of throttle body manufacture. TPS adjustments should only be made if the TPS was loosened, repositioned, or replaced. Any adjustments made to the idle air gap screw, TPS sensor, or throttle synchronization screw should only be performed when directed to so by the Digital Wrench®...

  • Page 210: Tps Tests

    Cleanfire Fuel Injection TPS Tests Two tests can be performed to quickly determine if further testing is required. TEST 1: TPS Idle Voltage 1. Connect Digital Wrench® to the vehicle. Confirm the throttle lever free play is set to specification, and the throttle cable is not pulling on the throttle plate cam.

  • Page 211: Tps Set Procedure Menu

    Cleanfire Fuel Injection TPS Set Procedure Menu The TPS Set Procedure Menu must be accessed to perform the following procedures: • Idle Voltage Setting Adjustment • Base and Idle Voltage Adjustments - TPS Replacement • Throttle Body Synchronization-Full Adjustment Procedure To access the TPS Set Procedure Menu, click on the Special Tests (Red Tool Box) button.
  • Page 212 Cleanfire Fuel Injection The next screen will display the current idle voltage setting. The text will match the voltage specification required by the vehicle. If the voltage is within specification, the dialogue box will indicate the current TPS setting is within specifications, and the CONTINUE button will be RED.
  • Page 213 Cleanfire Fuel Injection This is the TPS Initialization Procedure screen. A detailed description of each procedure is outlined below. IDLE SETTING Access the Idle Setting procedure to set the idle speed voltage. Digital Wrench® will guide the technician through the process for setting the TPS idle voltage.
  • Page 214 Cleanfire Fuel Injection BASE AND IDLE SETTING CAUTION The throttle position sensor (TPS) is set at the time of throttle body manufacture. TPS adjustments should only be made if the TPS was loosened, repositioned, or replaced. Any adjustments made to the idle air gap screw, TPS sensor, or throttle synchronization screw should only be performed when directed to so by the Digital Wrench®...

  • Page 215: Throttle Position Sensor (Tps) Wire Harness Routing

    NOTE: The TPS connectors must be clean and dry. these guidelines: Blow dry with compressed air. Do not apply dielectric grease to terminals. • Use the recommended oil. Polaris recommends VES Gold Plus engine oil for maximum VES performance. WIRE LOOP •...

  • Page 216: Electronic Reverse (Perc)

    Cleanfire Fuel Injection ELECTRONIC REVERSE (PERC) NOTE: Maximum RPM in reverse is 6000 RPM. NOTE: If the engine stops running or is shut off Overview while in reverse. The engine will start in forward gear. The operation of the electronic reverse system is achieved by automatically reversing the engine rotation with a push FORWARD OPERATION of a button.

  • Page 217: Altitude Setting

    If your engine is carbureted, you can adjust the elevation • Max RPM for operating in reverse = 6000 RPM setting of the Polaris electric reverse control (PERC). If your engine is a Cleanfire system, this is automatically • Engine must first reach 900 RPM at start up before done through the engine controller unit (ECU), and you do the reverse system can be used.

  • Page 218: Troubleshooting

    Cleanfire Fuel Injection TROUBLESHOOTING Poor Performance • Fuel quality. Use recommended fuel (91 octane Engine Will Not Start minimum). • Is the key inserted in key switch and turned to • Ethanol/Non-ethanol fuel resistor plug. Is the RUN? correct fuel selector plug connected for the type of fuel in the tank? •...

  • Page 219: Dc-Cfi Troubleshooting Flowchart

    Fuel octane not known, < 91+ octane, or any 87+ octane oxygenated (ethanol, MTBE, etc, blended) fuel = 24 OHM Resistor 91+ octane non-oxygenated (non-ethanol) fuel = 160 OHM Resistor DIGITAL WRENCH (DW) STEP 2 1. Is DW the most current version? Check the DW update site (http://polaris.diagsys.com/modules.php?name=Downloads) to review and Using download any available updates. Digital 2.

  • Page 220: Detonation Limit Troubleshooting Flowchart

    Fuel octane not known, < 91+ octane, or any 87+ octane oxygenated (ethanol, MTBE, etc, blended) fuel = 24 OHM Resistor 91+ octane non-oxygenated (non-ethanol) fuel = 160 OHM Resistor DIGITAL WRENCH (DW) STEP 2 1. Is DW the most current version? Check the DW update site (http://polaris.diagsys.com/modules.php?name=Downloads) to review and Using download any available updates. Digital 2.
  • Page 221 Final Drive/Brake System CHAPTER 5 Final Drive/Brake System TRACK STUD SPECIFICATIONS ......... . . 5.2 TRACK STUDDING.

  • Page 222: Track Stud Specifications

    Final Drive/Brake System TRACK STUD SPECIFICATIONS NOTE: 2012-2013 Rush 121/Switchback 136 models with Cobra track feature additional wear strips installed into integrated coolers. The wear strips must Track Studding be installed on any 2012-2013 Rush 121/Switchback 136 equipped with a Cobra track. CAUTION 121 Integrated Cooler Wear Strip: 5137678 x 2qty....

  • Page 223: Drive Gears/Chains

    Final Drive/Brake System DRIVE GEARS/CHAINS Drive Gears PART NUMBER DESCRIPTION 3221095 19T, 3/4W, 15 SPL, HYVO, PM 3221096 20T, 3/4W, 15 SPL, HYVO, PM 3221097 21T, 3/4W, 15 SPL, HYVO, PM 3221098 22T, 3/4W, 15 SPL, HYVO, PM 3221099 23T, 3/4W, 15 SPL, HYVO, PM 3221101 24T, 3/4W, 15 SPL, HYVO, PM 3221102...

  • Page 224: Gear Ratio Speed Chart

    Final Drive/Brake System GEAR RATIO SPEED CHART chaincase. MPH speed is the theoretical speed when the drive and driven clutches are at a 1:1 ratio. The following gear and chain combinations are acceptable for use with the 7.53 center distance 7.53 CD Chaincase Speed Chart ENGINE RPM 8250...

  • Page 225: Chaincase

    Brake Caliper Types Phantom Specifications/Torque Guide -Fixed Caliper, Dual Floating Pistons COMPONENT TORQUE SPEC Lubricant Polaris 80W SCL Capacity 9oz. (266 ml) Cover Fasteners 9.5 ft-lbs (13 Nm) (Follow Torque Pattern) Chain Tensioner Jam Nut 21 ft-lbs (28 Nm) Fill Plug 6 - 9.5 ft-lbs (8 - 13 Nm)

  • Page 226: Full Assembly View

    Final Drive/Brake System Full Assembly View REFERENCE DESCRIPTION REFERENCE DESCRIPTION Brake Disc Fastener Snap Rings Phantom Caliper Models = Flat Washer Bearings Phantom Lite Caliper Models = Domed Chain Tensioner/Wear Pad (Beveled) Washer Tensioner Adjustment Screw/Jam Nut Brake Disc Vent Seal Sleeve Fill/Drain Plugs Jackshaft O-Ring...

  • Page 227: Chaincase Disassembly

    Final Drive/Brake System Chaincase Disassembly 9. Remove the brake disc from the jackshaft. Reference table for brake disc hardware. 1. Remove the left and right door panels. Remove the screw securing the right lower fender to the chassis. YEAR 2. Remove the hood assembly. BRAKE DISC FASTENER HARDWARE CALIPER TYPE 3.

  • Page 228: Chaincase Assembly

    Final Drive/Brake System 18. Loosen the chain adjuster screw. Remove the tensioner pad, upper and lower gears, and chain. GEARS/CHAIN O-RING SEAL SLEEVE 12. Remove the cover fasteners. Chaincase Assembly 13. Carefully remove the cover. Use a flat blade 1. Thoroughly clean the chaincase, gears, and chain. screwdriver at the pry points to aid removal.
  • Page 229 Final Drive/Brake System 13. Install cover screws. Torque screws 20. Install the exhaust silencer. Verify the outlet boot is specification using the specified sequence. See installed correctly around the silencer outlet tube. “Chaincase Cover Torque Pattern” on page 5.5. 21. Install the screw securing the right fender to the chassis.

  • Page 230: Mounting Assembly View

    Final Drive/Brake System Mounting Assembly View Stud Plate-RMK Models Only Tunnel Reinforcement Plate-Switchback Only Align with bulkhead cooler. NOTE: 2012-2013 Pro-Ride models feature a bonded 3. Remove the fasteners securing the chaincase to the chaincase. tunnel, front cooler/closeoff panel, and side support. 4.

  • Page 231: Bonded Chaincase Removal/Installation

    Final Drive/Brake System Bonded Chaincase Removal/Installation 1. Follow the procedures for chaincase disassembly. 2. Follow the procedures for removing the track, rear suspension, and driveshaft. 3. Remove the fasteners securing the chaincase to the ADHESIVE tunnel, front cooler/closeoff panel, and side support. LINE 4.

  • Page 232: Quickdrive™ Low Inertia Drive System

    Final Drive/Brake System QUICKDRIVE™ LOW INERTIA DRIVE SYSTEM Specifications/Torque Guide COMPONENT TORQUE Upper/Lower Sprocket 30 ft-lbs (40 Nm) Fasteners Assembly View QuickDrive Low Inertia Drive System Assembly Backer Plate Lower Sprocket Sealed Bearings Domed Washers Snap Rings Fasteners Brake Disc Drive Belt Upper Sprocket 5.12...

  • Page 233: Quickdrive ™Drive Belt / Sprocket Removal

    Final Drive/Brake System QuickDrive ™Drive Belt / Sprocket Removal 3. Lock the parking brake. Remove the upper and lower sprocket fasteners. Discard both fasteners. CAUTION Exhaust components may be hot. Allow exhaust system to cool. Avoid pinch points between sprockets and brake disc.

  • Page 234: Quickdrive ™Drive Belt / Sprocket Installation

    Final Drive/Brake System QuickDrive ™Drive Belt / Sprocket 4. Working from the fuel tank side of the vehicle, install Installation the upper sprocket onto the jackshaft. After the sprocket engages the jackshaft splines, install the lower sprocket onto the driveshaft. CAUTION Exhaust components may be hot.

  • Page 235: Quickdrive™ Backer Plate Assembly View

    Final Drive/Brake System QuickDrive™ Backer Plate Assembly View COMPONENT TORQUE Screw (M8 1.25x35) 26 ft-lbs (35 Nm) Screw (M8 1.25x30) 26 ft-lbs (35 Nm) Screws (M6 1.0x22) 9 ft-lbs (12 Nm) QuickDrive™ Backer Plate Assembly Backer Plate Washers Stud Plate Nuts (M6) Screw (M8 1.25x35) Nut (M8)

  • Page 236: Quickdrive™ Backer Plate Removal

    Final Drive/Brake System QuickDrive™ Backer Plate Removal 4. Remove speed sensor from backer plate. NOTE: The backer plate is a structural component of the chassis and bonded with adhesive to the tunnel. Heating the backer plate with a torch is required for removal.

  • Page 237: Quickdrive™ Backer Plate Installation

    Final Drive/Brake System QuickDrive™ Backer Plate Installation See “QuickDrive™ Backer Plate Assembly View” on page 5.15. 1. Begin backer plate installation by verifying all fasteners are accounted for and staged for installation. 2. Verify the backer plate and tunnel mating surfaces are clean and free of dirt, and oil residue.

  • Page 238: Driveshaft/Jackshaft

    Final Drive/Brake System DRIVESHAFT/JACKSHAFT Specifications/Torque Guide COMPONENT TORQUE Jackshaft Flange Nuts 18 ft-lbs (25 Nm) Speedometer Flange Nuts 18 ft-lbs (25 Nm) Driveshaft Flange Nuts 18 ft-lbs (25 Nm) Driven Clutch Fastener 18 ft-lbs 25 Nm) Speed Sensor Screw 18 ft-lbs 25 Nm) Assembly View NUT PLATE-2011-CURRENT NOTE: The PTO ends of the jackshaft/driveshaft...

  • Page 239: Jackshaft Removal

    Final Drive/Brake System Jackshaft Removal 7. Inspect the gasket. Replace if worn or damaged. 1. Follow the procedures for chaincase disassembly or Driveshaft Installation drive belt/sprocket/backer plate disassembly. 1. From underneath the tunnel, insert the flangette-side 2. Remove the driven clutch assembly. of the driveshaft through the bulkhead.

  • Page 240: Brake System

    Final Drive/Brake System BRAKE SYSTEM Keep these points in mind when bleeding hydraulic brakes: General Guidelines • The master cylinder reservoirs have limited capacities. It is easy to empty them during the WARNING bleeding procedure. This introduces air into the system which you are trying to purge.

  • Page 241: Overview

    Final Drive/Brake System Overview The Polaris snowmobile hydraulic brake system consists fluid level mark on the inside of the reservoir, 1/4” - 5/16” of the following components or assemblies: brake lever, (.6 -.8 cm) below lip of reservoir opening. master cylinder, hydraulic hose, brake caliper (slave...

  • Page 242: Brake Fluid Replacement & Bleeding

    Final Drive/Brake System Brake Fluid Replacement & Bleeding 5. Fully apply the brake and hold, check for air bubbles rising in the fluid, indicating that air is being forced out Each hydraulic brake is fitted with a bleeder valve and a of the system.

  • Page 243: Combined Master Cylinder/Lever Service

    Final Drive/Brake System Combined Master Cylinder/Lever Service Remove the parking brake lever. 4. To remove the cartridge, completely drain the brake COVER SCREWS fluid from the housing. Remove the brake and parking brake levers. COVER 5. Disconnect the brake hose from the cartridge. Carefully pop the cartridge out of the housing.

  • Page 244: Brake Line Replacement

    Final Drive/Brake System Brake Line Replacement 10. Install new brake line on caliper and orientate it as noted in step 4. Brake Caliper Banjo Bolt: BRAKE HOSE FITTING 240-264 in-lbs (27-30Nm) 11. Insert the new brake line and install into the master cylinder.

  • Page 245: Brake Hose Routing

    Final Drive/Brake System Combined MC Brake Light Switch 14. On combined master cylinders, place the switch pack Replacement with the master cylinder onto the handle bar. Two smaller screws should be placed on the top and the 1. Remove the 4 screws that hold the master cylinder to longest screw is placed on the lower right.

  • Page 246: Phantom Brake Caliper Removal

    Final Drive/Brake System Phantom Brake Caliper Removal Phantom Brake Caliper Piston and Seal Replacement SILENCER BRACKET 600 RUSH DC-CFI-4 MODELS ONLY ALL OTHER PHANTOM=WASHERS PISTON SEAL PISTONS CALIPER BORE PLUG DO NOT PUSH OR MOVE! PISTON SEAL 1. Remove the two caliper bolts that hold the caliper and silencer bracket to the chaincase.

  • Page 247: Phantom Brake Pad Replacement

    Final Drive/Brake System 5. Position the caliper over the steel plate with the plate 12. Coat the piston thoroughly with new brake fluid. firmly against one of the retracted pistons. Evenly insert each piston into the bores, working each in by hand carefully and slowly. Push each piston CAUTION down until bottomed out.

  • Page 248: Phantom Lite Brake Caliper Bracket/Seal/Piston Service

    Final Drive/Brake System Phantom Lite Brake Caliper Bracket/Seal/ Piston Service SPRINGS CAUTION NEVER RE-USE PISTON SEALS. ALWAYS REPLACE WITH NEW PARTS. DO NOT ATTEMPT TO SAND OR POLISH A CALIPER PISTON. 5. Push the caliper mounting bracket against caliper. 6. Remove both friction pads. 1.
  • Page 249 Final Drive/Brake System 8. Remove the two small and two large o-rings from the 15. Coat the piston thoroughly with new brake fluid. inside of mounting ears on caliper. Discard the o- Evenly insert piston into the bore, working it in by hand rings.

  • Page 250: Phantom Lite Brake Pad Replacement

    Final Drive/Brake System Phantom Lite Brake Pad Replacement 11. Check master cylinder reservoir for proper fluid level and replace cover. Torque screws to specification. NOTE: Always replace both friction Brake Pad pads at the same time. Brake pads need to be replaced if the Master Cylinder Reservoir Screws: thickness of the friction material is less 240-264 in-lbs (27-30Nm)

  • Page 251: Brake Disc Replacement

    Final Drive/Brake System Brake Disc Replacement Brake Disc Service Specifications: • Lateral Run-Out Service Limit = .010" (.254mm) NOTE: Reference Brake Disc Hardware table before reinstalling brake disc. • Service Limit Thickness = .030" (.762mm) less than nominal YEAR BRAKE DISC FASTENER HARDWARE •...
  • Page 252 Final Drive/Brake System NOTES 5.32...
  • Page 253 POLARIS P2 TABBED DRIVEN SPRINGS ........6.9...

  • Page 254: Pvt System

    RPM, but never below, after the driven or repairs. clutch begins to open. The Polaris drive system is a centrifugally actuated Shift Out RPM variable speed belt drive unit. The drive clutch, driven clutch, and belt make up the torque converter system.
  • Page 255 PVT System Back-Shifting Driven Helix / Ramp Back-shifting occurs when the track encounters an The helix cam is the primary torque feedback component increased load (demand for more torque). Back-shifting is within the driven clutch, regardless of driven clutch type. a function of a higher shift force within the driven clutch The beginning angle of the helix must transmit enough than within the drive clutch.

  • Page 256: General Information

    Spring-Loaded Roller Pin Installation Roller/Bushing Alignment Tool 8700221 Drive Clutch Compression Tool (Compresses drive clutch without removing clutch from engine.) 2871173 NOTE: Polaris dealers can order the tools listed above through the SPX Service Tools catalog or by calling SPX @ 1-800-328-6657.

  • Page 257: Drive Clutch Springs

    PVT System Drive Clutch Springs WIRE FORCE LBS. LOAD FREE LENGTH +/- PART NUMBER COLOR DIAMETER @ 2.50” - 1.19” RATE (lbs./ .125” (inches) (+/- 12 LBS.) inch) 7041080 Blue .207 3.55 120 - 300 7041945 Almond .218 3.65 140 - 330 7041645 Almond/Gold .207...

  • Page 258: Spring Free Length

    PVT System Spring Free Length Drive Clutch Weights Measure the drive and driven spring free length with the 10 Series Weights spring resting on a flat surface. Replace spring if out of specification. VERIFY SPRING COILS ARE PARALLEL WEIGHT GRAMS(+/- 1gr.) PART NUMBER COILS ARE NOT DISTORTED/CRACKED 10M - R 1321530...

  • Page 259: Perc Team Lwt Driven Helixes (24 Fin)

    PVT System PERC Team LWT Driven Helixes (24 Fin) 11 Series Weights PART NUMBER DESCRIPTION 5135401 64 / 42 - .36 5135402 64 / 38 - .25 5135403 56 / 42 - .36 5135503 54 / 38 - .25 5135504 5135772 66 / 44 - .46 5136327...

  • Page 260: Team Driven Springs

    PVT System Team Driven Springs TEAM Driven Springs PART Free Length COLOR LOAD @ 2.2(lbs) LOAD @ 1.1(lbs) Rate (Lbs. per inch) NUMBER Inches (cm) 7042181 Black/Yellow 6.0 (15.24) 7043058 Red/Black Subs to 7043149 - P2 Non-Tabbed 7043059 Red/Green 4.767 (12.1) 7042066 Green/Black 5.60 (14.2)

  • Page 261: Polaris P2 Driven Non-Tabbed Springs

    PVT System Polaris P2 Driven Non-Tabbed Springs TEAM PART Free Length EQUIVALENT COLOR LOAD @ 2.2(lbs) LOAD @ 1.1(lbs) Rate (Lbs./In.) NUMBER Inches (cm) COLOR RED/YELLOW 7043397 4.4 (11.2) RED/SILVER 7043398 4.95 (12.6) RED/BLUE 7043151 4.76 (12.1) BLACK 7043150 BLACK 4.2 (10.6)

  • Page 262: Polaris P2 Driven Helixes

    PVT System Polaris P2 Driven Helixes Arc to Straight Angle Helix: 56/42 .45 Example 1st Angle at .100” from Horizontal / 2nd Angle - Vertical Distance to Transition PART NUMBER DESCRIPTION 5136975 5137154 5137155 5137160 5137142 58/40 - .35 5137150 40/38 - .45...

  • Page 263: Drive Belts

    PVT System Drive Belts Center Projected Outer Overall Part Width Circumference Side Ride Out Notes Number Center Angle MBL Kevlar Cords Belt cord line Performance replacement for the 3211122 should be flush 3211080 with, or slightly Cut Finish 11.5 / °...

  • Page 264: Belt Wear / Burn Diagnostics

    PVT System Belt Wear / Burn Diagnostics POSSIBLE CAUSE SOLUTION Drive at higher RPM if possible. Gear the machine Driving at or about engagement RPM for extended down. Make sure belt deflection is at 1 1/4” to achieve periods of time in any type of snow condition. optimum starting ratio.

  • Page 265: Drive Belt Removal - Team Driven

    PVT System Drive Belt Removal - Team Driven NOTE: Turn the key to the “OFF” position and allow Adjusting Belt Deflection - Team Driven Clutch the engine to come to a complete stop. 1. Verify the driven clutch is not in reverse. Remove the LH compartment door panel.

  • Page 266: Drive Belt Removal - Spa P2

    PVT System Drive Belt Removal - SPA P2 Drive Belt Installation - SPA P2 1. With the L wrench inserted into one of the threaded holes and the sheaves in the open position, install the drive belt. NOTE: Install belt so that the numbers can be read correctly on the left side of the machine or in the direction in which the belt was originally installed.

  • Page 267: Pvt System Adjustments

    PVT System PVT SYSTEM ADJUSTMENTS Driven Clutch Offset/Shim Washers Clutch Alignment/Offset Offset Washers The drive and driven clutches are offset from each other. 16 Gauge Bushing=7556509 (QTY.1) This offset is controlled by the number and thickness of .023” = 7555917 (AR) washers installed on the jackshaft behind the driven .120”...

  • Page 268: Adjusting Engine Mount Bolts/Engine Alignment

    PVT System Adjusting Engine Mount Bolts/Engine 4. Once clutch alignment is set, tighten the engine mount Alignment bolts to specification in the sequence shown in the illustration. Minor adjustments to the engine mount bolts and MAG- front engine mount can be performed if the alignment tool indicates major clutch mis-alignment.

  • Page 269: Drive Clutch

    PVT System DRIVE CLUTCH Identification Every clutch will have the clutch part numbers etched on clutch puller, and repeat this step. to the cover (A). The “X" (B) marking is an index mark CAUTION where the clutch cover (C), clutch spider (D) and the stationary sheave (E) should line up when the clutch is assembled.

  • Page 270: Drive Clutch Disassembly

    PVT System Drive Clutch Disassembly WEIGHT ROLLER WEIGHT PIN WASHER ROLLER PIN SPIDER BUTTON SHIM BEARING SLEEVE MOVEABLE INSERT SPRING JAM NUT COVER SPIDER SPACERS COVER BEARING RETAINER MOVEABLE SHEAVE CLUTCH SPACER STATIONARY SHEAVE 8. Mount the drive clutch securely in a drive clutch holding fixture (PN 2871358).

  • Page 271: Roller Removal

    PVT System Roller Removal Spider Button Installation 1. A shim kit is available which contains an assortment of shims. BUTTON Drive Clutch Shim Kit ROLLER PIN PN 2200387 SPIDER 2. Measure the width of the moveable sheave towers and record. Specification is 1.50"+/- .001" (38.1mm). WASHER SHIM ROLLER...

  • Page 272: Bushing/Insert Replacement

    PVT System Bushing/Insert Replacement 11. Insert installation tool (Item 1) into center of sheave and with the towers pointing toward the vise (down), The drive clutch moveable sheave and cover bushings/ slide the sheave onto the puller rod. insert are replaceable. Bushing/insert removal and 12.

  • Page 273: Clutch Assembly

    PVT System Clutch Assembly 9. Apply Loctite® 243™ to shaft threads. Do not get Loctite® on moveable bushing.Install the jam nut onto 1. Assemble the rollers, bushings and roller pins if they the shaft and torque it to specification. were removed. 2.

  • Page 274: Spider Indexing

    PVT System clutch sheaves. Measure the opposite side gap using a feeler gauge. 3. A slight drag should be felt when inserting the feeler gauge between the belt and sheave face. 4. Compare measured gap to the specification. SPIDER The distance between the moveable and stationary clutch sheaves and thus the belt-to-sheave clearance is determined by the number and thickness of the washer(s) installed between the spider and clutch spacer.

  • Page 275: Drive Clutch Installation

    PVT System DRIVEN CLUTCH Re-indexing the spider 1/3 turn clockwise, or 1 leg, will allow the realignment of the moveable and stationary sheaves as previously marked (D). For EXAMPLE: 0.020" Driven Clutch Removal or 0.032" (0.5 - 0.8mm) washer removed - re-index spider clockwise 1/3 turn.

  • Page 276: Team Lwt Components

    PVT System Team LWT Components SCREWS ROLLER ASSEMBLY HELIX SNAP RING SPRING CUP DEFLECTION SPACER SPRING STATIONARY SHEEVE MOVEABLE SHEEVE BELT DEFLECTION SCREW double splines on the shaft. Slowly compress the spring and roller assembly down on to the shaft. Install the snap ring making sure it is fully seated in the groove.

  • Page 277: Polaris Spa-P2 Driven Clutch Components

    PVT System Polaris SPA-P2 Driven Clutch Components SPACER STATIONARY SHEAVE MOVEABLE SHEAVE WASHER DRIVEN COVER SPRING w/TAB HELIX SPRING CUP w/TAB HOLES BUSHING SPACER ROLLER BUSHING (NO SERVICE) RETAINING RING (NO SERVICE) WASHER ADJUSTER SCREW / LOCK NUT 3. Remove the snap ring. Verify the washer is not lodged inside the snap ring groove.

  • Page 278: Pvt System Troubleshooting

    PVT System 12. Align the helix alignment hole with the “X” on the • PREMATURE WEAR: Ensure correct belt is moveable sheave. installed. Inspect belt-to-sheave clearance, deflection, and clutch alignment. Adjust gearing for rider type. Verify correct clutch weight/spring package is installed. Change riding habits/style.
  • Page 279 Shocks CHAPTER 7 Shocks SPECIAL TOOLS............7.2 SHOCK REBUILDING TOOLS .

  • Page 280: Special Tools

    DESCRIPTION 2871232 FOX™ Shock Spanner PS-44925 FOX™ Inner Tube Puller (Position Sensitive Shocks) PU-51039 Top Fill Shock Fill Tool NOTE: Polaris dealers can order the tools listed above through the SPX Service Tools catalog or by calling SPX @ 1-800-328-6657.

  • Page 281: Valve Shims

    Shocks VALVE SHIMS FOX™ Shock Valve Part Numbers PART NUMBER SIZE THICKNESS 1500055 0.700 1500054 0.800 1500053 0.900 1500048 1.000 0.006 1500049 1.100 1500050 1.250 1500052 1.300 1500029 0.700 1500028 0.800 1500033 0.900 1500032 1.000 0.008 1500031 1.100 1500051 1.250 1500030 1.300 1500044...

  • Page 282: Walker Evans™ Shock 3/8" Valve Part Numbers

    Shocks Walker Evans™ Shock 3/8" Valve Part Numbers PART NUMBER SIZE THICKNESS 1800051 .700 1800075 .800 1800076 .900 1800077 1.000 .006 1800078 1.100 1800079 1.200 1800080 1.300 1800081 .700 1800082 .800 1800083 .900 1800084 1.000 .008 1800085 1.100 1800086 1.200 1800087 1.250 1800088...

  • Page 283: Valve Shim Arrangement

    Shocks Valve Shim Arrangement NOTE: The rebound and compression valve stacks will always be positioned as shown in the illustration, Shown below is an example of how valve stacks are regardless of how the shock assembly is installed on arranged. the snowmobile.

  • Page 284: Specifications

    Shocks SPECIFICATIONS Valve shim stacks listed as they would appear on the shaft when shock rod is locked in a table vise (eyelet down, threaded end up). 2010 Rush Shock Specifications NOTE: All valve code measurements are in inches.  2010 IFS Shock XTENDED OLLAPSED...
  • Page 285 Shocks 2010 Front Track Shock (FTS) XTENDED OLLAPSED HOCK IFP D TROKE EPTH SHOCK PN MODEL ENGTH ENGTH OLUME 7043412 Walker Evans™ 11.75 7.98 3.77 .625 2.25 Full 2010 Front Track Shock SHOCK 7043412 .625 x .065 .700 x .008 .800 x .008 .900 x .008 1.00 x .008...
  • Page 286 Shocks 2010 Rear Track Shock (RTS) XTENDED OLLAPSED HOCK IFP D TROKE EPTH SHOCK PN ODEL ENGTH ENGTH OLUME 7043417 Walker Evans™ 17.25 12.00 5.25 .625 2.00 Full 2010 Rear Track Shock SHOCK 7043417 .625 x .065 .700 x .015 .800 x .015 .900 x .015 1.00 x .015...

  • Page 287: 2011 Pro-Ride Model Shock Specifications

    Shocks 2011 PRO-RIDE Model Shock Specifications Valve shim stacks listed as they would appear on the shaft when shock rod is locked in a table vise (eyelet NOTE: All valve code measurements are in inches. down, threaded end up).  2011 IFS Shocks EXTENDED COLLAPSED...
  • Page 288 Shocks 2011 Front Track Shocks (FTS) EXTENDED COLLAPSED SHOCK STROKE IFP DEPTH SHOCK PN MODEL LENGTH LENGTH VOLUME 7043632 FOX™ 11.67 8.33 3.34 .498 7043642 11.67 8.33 3.34 2.25 .625 7043634 12.34 8.84 Full Walker Evans ™ 7043628 11.75 8.21 3.54 4.30 7043602...
  • Page 289 Shocks 2011 Rear Track Shocks (RTS) EXTENDED COLLAPSED SHOCK STROKE IFP DEPTH SHOCK PN MODEL LENGTH LENGTH OIL VOLUME 7043633 FOX™ 17.29 12.06 5.23 .498 2.26 7043651 17.25 12.0 5.25 .625 7043635 16.71 10.96 5.75 2.25 Full Walker Evans ™ 7043629 .625 16.8...

  • Page 290: 2012 Pro-Ride Model Shock Specifications

    Shocks 2012 PRO-RIDE Model Shock Specifications Valve shim stacks listed as they would appear on the shaft when shock rod is locked in a table vise (eyelet NOTE: All valve code measurements are in inches. down, threaded end up).  2012 IFS Shocks EXTENDED COLLAPSED...
  • Page 291 Shocks 2012 Front Track Shocks (FTS) EXTENDED COLLAPSED SHOCK STROKE IFP DEPTH SHOCK PN MODEL LENGTH LENGTH VOLUME 7043634 12.34 8.84 .625 7043628 Walker Evans ™ 11.75 8.21 3.54 7043602 7043737 FOX™ 12.27 8.63 3.64 .498 Full 7043738 Walker Evans 12.25 8.64 3.61...
  • Page 292 Shocks 2012 Rear Track Shocks (RTS) EXTENDED COLLAPSED SHOCK STROKE IFP DEPTH SHOCK PN MODEL LENGTH LENGTH OIL VOLUME 7043721 FOX™ 17.29 12.06 5.23 .498 2.26 7043723 17.25 12.0 5.25 .625 7043635 16.71 10.96 5.75 2.25 Full Walker Evans ™ 7043629 .625 16.80...
  • Page 293 Shocks 2013 PRO-RIDE Model Shock Specifications Valve shim stacks listed as they would appear on the shaft when shock rod is locked in a table vise (eyelet NOTE: All valve code measurements are in inches. down, threaded end up).  2013 IFS Shocks EXTENDED COLLAPSED...
  • Page 294 Shocks 2013 Front Track Shocks (FTS) EXTENDED COLLAPSED SHOCK STROKE IFP DEPTH SHOCK PN MODEL LENGTH LENGTH VOLUME 7043634 12.34 8.84 .625 7043628 Walker Evans ™ 11.75 8.21 3.54 7043602 7043737 FOX™ 12.27 8.63 3.64 .498 Full 7043779 FOX™ 12.05 8.62 3.43 .498...
  • Page 295 Shocks 2013 Rear Track Shocks (RTS) EXTENDED COLLAPSED SHOCK STROKE IFP DEPTH SHOCK PN MODEL LENGTH LENGTH OIL VOLUME 7043177 FOX™ 15.60 10.56 5.04 1.22 7043723 17.25 12.0 5.25 .625 7043635 Walker Evans 16.71 10.96 5.75 2.25 ™ Full 7043629 16.80 11.35 5.45...

  • Page 296: Shock Maintenance

    Shocks SHOCK MAINTENANCE Walker Evans Remote Reservoir / ™ Piggyback Shock Disassembly Walker Evans Coil-Over Piggyback Shock ™ NOTE: Remote reservoir shock shown. IMPORTANT: To prevent damage or marks to the shock, the use of soft jaws on a vise is recommended. COMPRESSION KNOB SCREW O-RING...
  • Page 297 Shocks 4. Press the end cap into the reservoir to access the NOTE: Place the valve stack on a clean shop towel in snap ring. case you have to move them. This will also help when assembling them back onto the shock rod. 5.
  • Page 298 Shocks Walker Evans Remote Reservoir / ™ Piggyback Shock Assembly CAUTION SHOCK CONTENTS UNDER HIGH PRESSURE. ALWAYS WEAR SAFETY GLASSES WHEN WORKING WITH SHOCKS. 1. Secure the shock rod in a vise with the threads of the rod facing up. 2.
  • Page 299 Shocks 12. Set the IFP so it is approximately 1/8 from the bottom IMPORTANT: Fast installation of the piston rod and of the reservoir. Install the bleed screw. assembly may displace the internal floating piston (IFP) from its original position. Performance issues will be a result if the IFP is not in its specified position.

  • Page 300: Fox™ Ifp Monotube Shock Disassembly

    Shocks FOX™ IFP Monotube Shock Disassembly Shock Components (Bearing Air Bleed) BODY CAP Shock Components (IFP Air Bleed) BODY CAP FILL PORT FILL PORT BLEED SCREW BLEED SCREW O-RING O-RING WEARBAND BLEED SCREW O-RING O-RING WEARBAND SPRING RETAINER O-RING SPRING RETAINER LOCK NUT REBOUND STACK BACKUP PLATE...

  • Page 301: Fox™ Ifp Monotube Shock Assembly

    Shocks FOX™ IFP Monotube Shock Assembly Shock Disassembly Shock Assembly - IFP Air Bleed Shocks CAUTION CAUTION SHOCK CONTENTS UNDER HIGH PRESSURE. ALWAYS WEAR SAFETY GLASSES WHEN SHOCK CONTENTS UNDER HIGH PRESSURE. WORKING WITH SHOCKS. ALWAYS WEAR SAFETY GLASSES WHEN WORKING WITH SHOCKS.
  • Page 302 Shocks FOX™ IFP Monotube Shock Assembly 11. After a few minutes, slowly and carefully pump the shock body up and down to force the oil through the Shock Assembly - Bearing Air Bleed Shocks valves stacks and piston orifices. Continue until air bubbles no longer rise to the surface of the oil.
  • Page 303 Shocks 12. Mount the body cap end of the shock in bench vise. Slowly fill 3/4 of the body tube with new shock oil. FOX™ 5W Shock Oil 2870995(Quart) 13. Allow the oil to sit for several minutes to allow air bubbles to escape.

  • Page 304: Walker Evans™ Ifp Monotube Shock

    Shocks Walker Evans IFP Monotube Shock Shock Disassembly ™ CAUTION O-RING SHOCK CONTENTS UNDER HIGH PRESSURE. FILL PORT ALWAYS WEAR SAFETY GLASSES WHEN WORKING WITH SHOCKS. BODY CAP O-RING 1. Remove the shock from the vehicle. Clean the shock BLEED SCREW assembly to remove all dirt and foreign material.
  • Page 305 Shocks Walker Evans IFP Monotube Shock 13. Allow the oil to sit for several minutes to allow air ™ Assembly bubbles to escape. Gently tap on the shock body to assist with removing any trapped air. Shock Assembly 14. Carefully install the shock rod/bearing into the shock body.

  • Page 306: Fox™ Ps-5 Assembly View

    Shocks FOX™ PS-5 Assembly View BUSHINGS O-RINGS CHARGE PORT BODY CAP O-RING BLEED SCREW/O-RING SHOCK BODY IFP WEAR BAND O-RING EXTERNAL COLLAR BYPASS SLEEVE BYPASS BAND WIRE RINGS O-RINGS LOCK NUT INTERNAL COLLAR WEAR BAND PISTON VALVE O-RINGS U-CUP SEAL FIST SCRAPER SNAP RING BEARING ASSEMBLY...

  • Page 307: Fox™ Ps-5 Disassembly

    Shocks FOX™ PS-5 DISASSEMBLY 7. Using the 1 3/8” wrench, loosen and unscrew the bearing assembly from the shock body. If the body cap unscrews instead of the bearing, that is OK. You WARNING will need to remove both for this rebuild procedure. Shocks contain high pressure nitrogen gas.
  • Page 308 Shocks 9. Remove the shaft assembly from the body tube, and 15. Hold the tip of a screwdriver against the end of shaft. place on a clean, lint free paper towel. Remove the Hold the piston assembly under the top-out plate and shock from the vice and pour shock oil into a proper lift upwards.
  • Page 309 Shocks 17. Remove the FIST scraper from the bearing assembly 22. Once the wire ring is removed, flip the shock body by removing the snap ring. The FIST scraper will fall around and push the bypass sleeve off of the shock out of the bearing.

  • Page 310: Fox™ Ps-5 Assembly

    Shocks FOX™ PS-5 ASSEMBLY 8. Place the shock rod eyelet in a bench vise with the threaded end up. 1. Thoroughly clean all of the components with solvent and allow to air dry. Discard all used wear bands and NOTE: If shock rod eyelet was serviced, install eyelet o-rings.
  • Page 311 Shocks 13. Remove shock rod assembly from vise. 16. Install shock rod assembly into shock body. Tighten bearing assembly to specification. 14. Assemble the bypass sleeve using a new bypass wear band and new o-rings. Install components as shown. Note that the bypass wear band covers the set of 3 bypass holes in the tube.
  • Page 312 Shocks 23. Install the IFP without the bleed screw into the shock 27. Install a new o-ring into the body cap. body. Set the IFP depth to the specifications noted at beginning of this chapter. O-RING 28. Apply Red thread lock to the first two threads of the body cap.

  • Page 313: Fox™ Zero Pro Assembly View

    Shocks FOX™ Zero PRO Assembly View TOP FILL PORT BODY CAP SLEEVE BUSHING AIR VALVE O-RING O-RING SPRING PRELOAD SHOCK BODY LOCK RING IFP DEPTH PRELOAD RING LOCK NUT PISTON VALVE WEAR BAND DU BUSHING O-RINGS SPRING INSTALLED BEARING ASSEMBLY LENGTH RETAINER RING SNAP RING...

  • Page 314: Fox™ Zero Pro Shock Disassembly

    Shocks FOX™ Zero PRO Shock Disassembly 3. Secure shock in a bench vise as shown below. Insert the Top Fill Shock Fill Tool (PU-51039) into the hole NOTE: Read through all of these instructions first to in the body. Depress the needle into the body cap to familiarize yourself with the rebuild procedure.
  • Page 315 Shocks 5. Depress the bearing assembly into the shock to 11. Remove and discard the o-ring from the bearing cap. expose the retaining ring. Retaining Ring Remove O-Ring NOTE: If the shock has been rebuilt several times, body cap assembly replacement is recommended as the air valve assembly is not serviceable.
  • Page 316 Shocks 14. Mount the shock rod assembly eyelet in a bench vise. 17. Use a snap ring pliers to remove the snap ring. Remove the piston valve lock nut. Remove the piston Remove the scraper and discard. Using a pick or valve, rebound, and compression shims as an scribe, pierce and remove the o-rings inside the assembly.

  • Page 317: Fox™ Zero Pro Shock Assembly

    Shocks FOX™ Zero Pro Shock Assembly 6. Install the shock shaft seal protector tool onto the shock shaft. Install the body cap, and then the bearing NOTE: The rebuild kit (PN: 1500710) will supply all of assembly onto the shock shaft. the required o-rings, wear bands and a u-cup seal....
  • Page 318 12. Apply Loctite Primer N to the shock body cap threads. Polaris Gas Shock Oil - 5 wt. PN 2870995 - qt. PN 2872279 - 2.5 gal. 18. Slide the bearing assembly down the shock shaft.
  • Page 319 Shocks 20. Carefully and slowly push the bearing down just past the retainer groove in the shock body. Install the retainer ring into the shock body. 21. Once the retainer ring is installed, slowly push the shock shaft down into the shock body. DO NOT PULL THE SHAFT OUT.
  • Page 320 Shocks NOTES 7.42...
  • Page 321 Steering and Suspensions CHAPTER 8 Steering and Suspensions OVERVIEW / SPECIFICATIONS..........8.3 INSPECTION .
  • Page 322 Steering and Suspensions REAR SUSPENSION ASSEMBLY ILLUSTRATIONS......8.36 INDY 121 CONVENTIONAL PIVOTS/REAR IDLER ......8.36 INDY 121 CONVENTIONAL RAIL ASSEMBLY .

  • Page 323: Overview / Specifications

    Make notes of the direction a bolt goes through a part, what type of nut is used in an application, etc. Always use genuine Polaris parts and hardware when PARALLEL replacing front end components. Review steering adjustment guidelines before making adjustments.
  • Page 324 Steering and Suspensions Front Suspension Type by Model Camber / Toe Specifications Maximum width and camber measurements are achieved FRONT SUSPENSION MODELS with the front end elevated and shocks at full extension. 2010-2011Rush/ Toe alignment is measured at ride height. This means that Pro-Ride Switchback Assault the machine is on the ground and resting at normal ride...

  • Page 325: Suspension Mounting Fastener Torque

    Suspension Mounting Fastener Torque Special Tools NOTE: Reference assembly illustrations for torque NOTE: Polaris dealers can order the tools listed in specifications not listed in table. this chapter through the SPX Service Tools catalog or by calling SPX @ 1-800-328-6657.

  • Page 326: Initial Shock Settings

    Steering and Suspensions Initial Shock Settings NOTE: A column for the RTS spring setting is not included as all vehicles require rider weight to set Use the Initial Shock Settings Table below to set the the spring length/SAG setting. This information is vehicle suspension to the original factory configuration.
  • Page 327 Steering and Suspensions Initial Shock Settings IFS SPRING FTS SPRING IFS SPRING IFS CLICKER FTS SPRING INSTALLED INSTALLED FTS CLICKER RTS CLICKER MODEL PRELOAD SETTING PRELOAD LENGTH LENGTH SETTING SETTING INCHES REBOUND INCHES INCHES INCHES 2013 Rush Base 3.75/9.5 2013 Rush PRO-R 2.0/5.08 3.0/7.6...

  • Page 328: Independent Front Suspension (Ifs) Shock Settings

    Steering and Suspensions Independent Front Suspension (IFS) Shock Settings MEASURING PRELOAD To change the IFS shock preload/installed spring height, raise the front of the snowmobile up and off the ground to remove the weight from the front suspension. Grasp the spring and rotate it.

  • Page 329: Rebound Adjustment

    Steering and Suspensions Walker Evans™ Spring Retainers Adjusting the IFS shock spring preload raises or lowers the front vehicle ride height and either increases or Some Walker Evans™ shocks feature a spring retainer decreases ski pressure when not accelerating. Increasing and a lock collar.

  • Page 330: Front Track Shock (Fts) Factory Settings

    Steering and Suspensions Front Track Shock (FTS) Factory Settings To change the FTS spring preload, carefully tip the snowmobile onto its left side to remove weight from the front track shock. Grasp the spring and rotate it. 2011-2013 RUSH/SWITCHBACK/RMK ASSAULT 2010 RUSH When decreasing FTS spring preload, make sure at least two turns of preload are holding the spring retainer against...

  • Page 331: Rear Track Shock (Rts) Factory Settings

    Steering and Suspensions Rear Track Shock (RTS) Factory Settings The RTS spring is the primary suspension setup and tuning component. For more information regarding how to set the spring preload and compression dampening, reference the Pro-Ride Progressive Suspension or Pro- Ride RMK Coil-Over Rear Suspension sections in this chapter.

  • Page 332: Limiter Straps - Indy / Rush / Rmk Models

    Steering and Suspensions Limiter Straps - INDY / RUSH / RMK Models Limiter Straps - Switchback 144 Models The limiter straps on INDY, RUSH Progressive and RMK The limiter straps on Switchback 144 rear suspensions Coil-Over rear suspensions are not adjustable. Drilling are adjustable.

  • Page 333: Torsion Springs/Sag Setting

    Steering and Suspensions Torsion Springs/SAG Setting 4. Again, measure the distance between the rear bumper and ground (Y). The INDY 121 and Switchback 144 rear suspensions are equipped with rear torsion springs. The spring preload can be set by adjusting the torsion spring preload blocks. The torsion spring preload sets the rear suspension SAG setting.

  • Page 334: Scissor Stop Adjustment - Indy Models

    Steering and Suspensions Scissor Stop Adjustment - INDY Models REAR TORQUE ARM REAR SCISSOR (PIVOT) REAR-REAR SCISSOR STOP FRONT REAR SCISSOR STOP The front rear scissor stop (FRSS) controls the bump attitude of the rear suspension. As the front torque arm (FTA) hits the bump, it forces the rear scissor to collapse a predetermined amount, depending on the FRSS block position.

  • Page 335: Front Suspension Assembly Illustrations

    Steering and Suspensions FRONT SUSPENSION ASSEMBLY ILLUSTRATIONS 2010 Pro-Ride Front Control Arms PIVOT SHAFTS MOUNTING STUDS BUSHINGS UPPER CONTROL ARM MOUNTING STUDS BUSHINGS SPINDLE LOWER CONTROL ARM SPHERICAL BEARING BUSHING WASHERS SNAP RING BUSHINGS CAUTION Never re-use lock nuts. Always re-assemble using new lock nuts.

  • Page 336: 2011 Pro-Ride Front Control Arms

    Steering and Suspensions 2011 Pro-Ride Front Control Arms PIVOT SHAFTS MOUNTING STUDS BUSHINGS UPPER CONTROL ARM SPRING WASHERS MOUNTING STUDS BUSHINGS SPINDLE LOWER CONTROL ARM BUSHINGS SPHERICAL BEARING WASHERS SNAP RING BUSHINGS CAUTION Never re-use lock nuts. Always re-assemble using new lock nuts.

  • Page 337: 2012-2013 Pro-Ride (Fixed Camber) Front Control Arms

    Steering and Suspensions 2012-2013 Pro-Ride (Fixed Camber) Front Control Arms MOUNTING STUDS BUSHINGS SNAP RING PIVOT SHAFTS SPHERICAL BEARING WASHERS MOUNTING STUDS UPPER CONTROL ARM PIVOT SHAFTS BUSHINGS SPINDLE LOWER CONTROL ARM SPHERICAL BEARING SNAP RING BUSHINGS WASHERS BUSHINGS CAUTION Never re-use lock nuts.

  • Page 338: Pro-Ride Rmk/Wide Adjustable Front Control Arms

    Steering and Suspensions Pro-Ride RMK/Wide Adjustable Front Control Arms MOUNTING STUDS BUSHINGS PIVOT SHAFTS UPPER CONTROL ARM SPRING WASHERS MOUNTING STUDS PIVOT SHAFTS BUSHINGS SPINDLE LOWER CONTROL ARM BUSHINGS SPHERICAL BEARING WASHERS SNAP RING BUSHINGS CAUTION Never re-use lock nuts. Always re-assemble using new lock nuts.

  • Page 339: Pro Rmk Bonded Front Control Arms

    Steering and Suspensions PRO RMK Bonded Front Control Arms MOUNTING STUDS BUSHINGS PIVOT SHAFTS UPPER CONTROL ARM SPRING WASHERS MOUNTING STUDS PIVOT SHAFTS BUSHINGS SPINDLE LOWER CONTROL ARM SPHERICAL BEARING WASHERS SNAP RING BUSHINGS BUSHINGS CAUTION Never re-use lock nuts. Always re-assemble using new lock nuts.

  • Page 340: 2010-2011 Rush Upper Steering Assembly

    Steering and Suspensions 2010-2011 Rush Upper Steering Assembly HANDLEBAR COVER HANDLEBAR HOOK HANDLEBAR CLAMPS INSTALL CLAMP BUSHINGS HERE RISER POST CLAMPS HANDLEBAR HOOK HANDLEBAR CLAMPS CLAMP BUSHINGS STEERING POST APPLY GREASE TO BUSHINGS PRIOR TO ASSEMBLY HAND GUARDS/MOUNTS NOTE: Assembly Notes CAUTION •...
  • Page 341 Steering and Suspensions 2012-2013 INDY Rush/Switchback Upper Steering Assembly 2013 INDY SP/RUSH/SWITCHBACK FEATURE FULL-LENGTH HANDLEBARS HANDLEBAR COVER HANDLEBAR HOOK INSTALL CLAMP BUSHINGS AS SHOWN WITH OFFSETS DOWN. GRIP RISER STEERING STRAP BUSHING SPACERS HANDLEBAR HOOK HANDLEBAR CLAMPS CLAMP BUSHINGS STEERING POST NOTE: Assembly Notes CAUTION •...

  • Page 342: Switchback Assault Upper Steering Assembly

    Steering and Suspensions Switchback Assault Upper Steering Assembly HANDLEBAR CLAMPS HANDLEBAR HOOK POST CLAMPS CLAMP BUSHINGS APPLY GREASE TO BUSHINGS PRIOR TO ASSEMBLY STEERING POST CAUTION Never re-use lock nuts. Always re-assemble using new lock nuts. A: 14.7 ft-lbs (20 Nm) B: 12 ft-lbs (16 Nm)...

  • Page 343: 600/800 Rmk Upper Steering Assembly

    Steering and Suspensions 600/800 RMK Upper Steering Assembly HANDLEBAR COVER MOUNTAIN BAR HANDLEBAR CLAMPS HANDLEBAR HOOK RISER HANDLEBAR CLAMPS CLAMP BUSHINGS STEERING STRAPS CLAMP BUSHINGS BUSHING SPACERS STEERING POST NOTE: Assembly Notes CAUTION • Install handlebar riser with FWD facing front of vehicle.

  • Page 344: 600/800 Pro Rmk/Rmk Assault Upper Steering Assembly

    Steering and Suspensions 600/800 PRO RMK/RMK Assault Upper Steering Assembly MOUNTAIN BAR HANDLEBAR CLAMPS HANDLEBAR HOOK STEERING STRAP CLAMP BUSHINGS STEERING STRAP BUSHING SPACERS STEERING POST CAUTION Never re-use lock nuts. Always re-assemble using new lock nuts. A: 14.7 ft-lbs (20 Nm) B: 12 ft-lbs (16 Nm)...

  • Page 345: Two Piece Throttle Control

    Steering and Suspensions Two Piece Throttle Control 5. Remove the throttle release switch from the throttle block. Note the orientation of the switch during Some models are equipped with a two-piece throttle removal. control on the handlebar. The two-piece throttle control is designed to be serviced without having to remove the grip and hand warmer element.

  • Page 346: 2010 Rush Lower Steering Assembly

    Steering and Suspensions 2010 Rush Lower Steering Assembly UPPER STEERING POST UPPER DRAG LINK BUSHINGS ROD END POST BRACKET LOWER STEERING POST FIXED LINK ROD END TIE ROD RETAINING RING BEARING BUSHING REDUCER SPACER STUD BEARING RETAINING RING SPACER IDLER ARM BEARING BUSHING REDUCER ROD END...

  • Page 347: 2011-2013 Indy/Rush/Switchback/Switchback Assault Lower Steering Assembly8.27

    Steering and Suspensions 2011-2013 INDY/Rush/Switchback/Switchback Assault Lower Steering Assembly UPPER STEERING POST FIXED DRAG LINK POST CAP STEERING POST BUSHINGS LOWER STEERING POST FIXED LINK BUSHING SPACERS ROD END RETAINING RING BEARING TIE ROD SPACER STUD RETAINING RING BUSHING REDUCER BEARING SPACER IDLER ARM...

  • Page 348: 2011-2013 Rmk/Pro Rmk/Rmk Assault Steering Assembly

    Steering and Suspensions 2011-2013 RMK/PRO RMK/RMK Assault Steering Assembly UPPER STEERING POST ROD END UPPER DRAG LINK POST CAP STEERING POST BUSHINGS LOWER STEERING POST FIXED LINK BUSHING SPACERS ROD END WASHERS TIE ROD RETAINING RING BEARING SPACER STUD RETAINING RING BUSHING REDUCER BEARING SPACER...

  • Page 349: 2010-2013 Sway Bar Assembly

    Steering and Suspensions 2010-2013 Sway Bar Assembly SWAY BAR BUSHINGS BUSHING BRACKET LINK CAUTION Never re-use lock nuts. Always re-assemble using new lock nuts. A: 7.4 ft-lbs (10 Nm) B: 15-22 ft-lbs (20-30 Nm) 8.29...

  • Page 350: Front Suspension Settings

    • LENGTH: 45” (114.3cm) 3. If the measurement is out of specification, inspect the • MATERIAL: C-1018 front suspension for damage. Replace damaged • Polaris PN: 5333508 (Order from tool vendor.) components. 4. If no damage is found, reset the camber. 8.30...

  • Page 351: Handlebar Centering

    Steering and Suspensions Handlebar Centering Remove the skis and ski bushings. 3. Verify the shocks are at full extension and that no IFS 1. Raise the vehicle to remove the skis. components are bent or damaged. Replace any 2. Verify the handlebars are straight. Measure from each component that is damaged before making any bar end to a common center point at the rear of the adjustments.

  • Page 352: Toe Adjustment

    Steering and Suspensions Toe Adjustment 10. Turn both tie rods equally to set ski toe. When finished, measurement (X) should be 0" - 1/8" wider Toe is adjusted with the shocks and skis installed. Track than measurement (Y). alignment must be correct before starting this process. 11.

  • Page 353: Front Suspension Disassembly / Assembly

    Steering and Suspensions FRONT SUSPENSION DISASSEMBLY 4. Remove the fasteners and washers securing the upper and lower control arms to the spindle. Note the / ASSEMBLY position of the washers. Spindle Removal NOTE: Images of RMK model. All models similar. Reference front control arm and lower steering sections in this chapter for steering tie rod and lower control arm fastener locations.

  • Page 354: Upper/Lower Control Arm Removal

    Steering and Suspensions Upper/Lower Control Arm Removal Upper/Lower Control Arm Installation 1. Remove ski assembly and spindle. 1. If replacing the pivot shafts, bushings, or rod ends, 2. Remove the sway bar link fastener. install the new parts. Reference the appropriate component assembly views for correct orientation of washers and bushings.

  • Page 355: Spherical Bearing Replacement

    Steering and Suspensions NOTE: Apply Polaris Premium Grease to pivot shafts. Verify pivot shaft mounting faces are free from grease. NO GREASE 3. Install components in reverse order of disassembly. Use new lock nuts where applicable. Torque fasteners to specifications.

  • Page 356: Rear Suspension Assembly Illustrations

    Steering and Suspensions REAR SUSPENSION ASSEMBLY ILLUSTRATIONS INDY 121 Conventional Pivots/Rear Idler SLEEVE SHOCK PIVOT BUSHING H BRACKET SPACER SHAFT INNER SHAFT SPACER BUSHING SPACER SPACER REAR PIVOT INNER SHAFT WASHERS WASHER WASHER WASHER SHAFT SHAFT WASHER WASHER STANDARD FASTENERS A: 45 ft-lbs (61 Nm) B: 35 ft-lbs (47.4 Nm) Assembly Notes...

  • Page 357: Indy 121 Conventional Rail Assembly

    Steering and Suspensions INDY 121 Conventional Rail Assembly RRSS BOGIE WHEEL FRSS BUMPER MOUNTS INSIDE OF RAIL BOGIE WHEEL RAIL BUMPER/BRACKET ADJUSTER BLOCK RIVETS REINFORCEMENT PLATE RAIL BUMPER WASHER WASHER BUSHING RAIL TIP SPRING ROLLER RAIL SLIDER STANDARD FASTENERS A: 3-6 ft-lbs (4-8 Nm) B: 4 ft-lbs (5.4 Nm)...

  • Page 358: Indy 121 Conventional Rail Fastener Locations

    Steering and Suspensions INDY 121 Conventional Rail Fastener Locations LEFT RAIL SHOWN Components/Fasteners: • A - Rail Tip • B - Limiter Strap Shaft • C - Rail Bumper • D - Optional Bogie Wheel Asm. (Mount to inside of right rail). •...

  • Page 359: Indy 121 Conventional Front/Rear Torque Arm

    Steering and Suspensions INDY 121 Conventional Front/Rear Torque Arm FRONT TORQUE ARM SHAFTS WASHER REAR PIVOT O-RING INNER SHAFT LIMITER STRAP INNER SHAFT CLIP BUSHINGS SPACER SPRING ADJUSTER CARRIER WHEEL WASHER SLEEVE SHOCK ROD INSTALL PLATE POINTED DOWN BUSHING BUSHING TORSION SPRING STANDARD FASTENERS FLANGE SHAFT...

  • Page 360: 2010 Progressive 120 Rail Assembly

    Steering and Suspensions 2010 Progressive 120 Rail Assembly TRACK TENSIONER BRACKET INSIDE OF RAIL RAIL BUMPER BOGIE WHEEL ASM. RAIL TIP RAIL SLIDER METRIC FASTENERS A: 7.4 ft-lbs (10 Nm) B: 4 ft-lbs (5.4 Nm) C: Torque nut until screw protrudes 7/32" (5.3mm) D: 17 ft-lbs (23 Nm)...

  • Page 361: 2010 Progressive 120 Rail Fastener Locations

    Steering and Suspensions 2010 Progressive 120 Rail Fastener Locations LEFT RAIL SHOWN Components/Fasteners: • A - Rail Tip • B - Limiter Strap Shaft • C - Rail Bumper • D - H Bracket/Bogie Wheel Shaft • E - Bogie Wheel Asm. (Mount to outside of rail). •...

  • Page 362: 2010 Progressive 120 Front Torque Arm Assembly

    Steering and Suspensions 2010 Progressive 120 Front Torque Arm Assembly INNER SHAFT SPACERS FTS CARRIER WHEELS FRONT TORQUE ARM PIVOT SHAFTS BUSHINGS BUSHINGS UPPER TORQUE ARM SHAFTS BUSHINGS LIMITER STRAPS INSTALL STRAPS RUBBER SIDE OUT METRIC FASTENERS A: 17 ft-lbs (23 Nm) B: 60 ft-lbs (80 Nm) Apply Loctite®...
  • Page 363 Steering and Suspensions 2010 Progressive 120 Idler Shaft Assembly H BRACKET REAR IDLER WHEELS WHEEL SPACERS INNER SHAFT SPACER SHAFT ADJUSTER BLOCK SHAFT SHAFT METRIC FASTENERS A: 33 ft-lbs (45 Nm) B: 60 ft-lbs (80 Nm) Assembly Notes • Never re-use lock nuts. Always replace with new parts. •...

  • Page 364: 2010 Progressive 120 Rear Crank/Rear Scissor Assembly

    Steering and Suspensions 2010 Progressive 120 Rear Crank/Rear Scissor Assembly REAR TRACK SHOCK BUSHING REAR CRANK BUSHING PLUGS BUSHING UPPER CARRIER WHEEL ASM. BUSHINGS BUSHINGS REAR PIVOT BUSHINGS METRIC FASTENERS A: 33 ft-lbs (45 Nm) B: 60 ft-lbs (80 Nm) Assembly Notes •...

  • Page 365: 2010 Progressive 120 Rear Bumper/Closeoff Assembly

    Steering and Suspensions 2010 Progressive 120 Rear Bumper/Closeoff Assembly REAR BUMPER REAR PIVOT MID FLAP UPPER FLAP REAR FLAP CLOSEOFF FLAP METRIC FASTENERS A: 7 ft-lbs (9.5 Nm) Assembly Notes • Never re-use lock nuts. Always replace with new parts. •...

  • Page 366: Progressive 121 Rail Assembly

    Steering and Suspensions Progressive 121 Rail Assembly INSIDE OF RAIL SUPPORT PLATE RAIL BUMPER SPACER TRACK TENSIONER BLOCK BUMPER LINER BOGIE WHEEL MOUNT RAIL TIP BOGIE WHEEL ASM. RAIL SLIDER METRIC FASTENERS A: 7.4 ft-lbs (10 Nm) B: 4 ft-lbs (5.4 Nm) C: Torque nut until screw protrudes 5mm...

  • Page 367: Progressive 121 Rail Fastener Locations

    Steering and Suspensions Progressive 121 Rail Fastener Locations LEFT RAIL SHOWN Components/Fasteners: • A - Rail Tip • B - Limiter Strap Shaft • C - Rail Bumper • D - Left Rail Front Holes - Bogie Wheel Asm. (Mount to outside of rail). •...

  • Page 368: Progressive 121 Front Torque Arm

    Steering and Suspensions Progressive 121 Front Torque Arm FRONT TRACK SHOCK BUSHING BUSHING UPPER TORQUE ARM SHAFTS PIVOT SHAFT FRONT TORQUE ARM BUSHING LIMITER STRAPS LIMITER STRAP SPACER INSTALL STRAPS RUBBER SIDE OUT METRIC FASTENERS A: 17 ft-lbs (23 Nm) B: 60 ft-lbs (80 Nm) Apply Loctite®...

  • Page 369: Progressive 121 Idler Shafts

    Steering and Suspensions Progressive 121 Idler Shafts REAR IDLER WHEELS WASHER ADJUSTER SPACER INNER SHAFT SPACER INSTALL TORQUE ARM BOLT IN THIS DIRECTION SHAFT ADJUSTER SPACER SHAFT INNER SHAFT SPACERS WASHERS ANODIZED SHAFT METRIC FASTENERS A: 33 ft-lbs (45 Nm) Apply Loctite® 262™ to threads B: 50 ft-lbs (67 Nm) Apply Loctite®...

  • Page 370: Progressive 121 Rear Crank/Rear Scissor Assembly

    Steering and Suspensions Progressive 121 Rear Crank/Rear Scissor Assembly CRANK BUSHINGS REAR CRANK CRANK BUSHINGS PIVOT BUSHINGS BUSHING PLUG CRANK BUSHINGS BUSHING SPACER PIVOT BUSHINGS WASHER UPPER CARRIER WHEEL ASM. WASHER SPACER REAR PIVOT BUSHING PIVOT SHAFTS BUSHING WASHERS METRIC FASTENERS A: 33 ft-lbs (44.7 Nm) B: 60 ft-lbs (80 Nm) Assembly Notes...
  • Page 371 Steering and Suspensions 2011 Progressive 121 Bumper/Closeoff Assembly REAR FLAP MID FLAP MID FLAP COOLER REAR BUMPER REAR PIVOT METRIC FASTENERS A: 33 ft-lbs (44.7 Nm) B: 3.6 ft-lbs (5 Nm) C: 9.5 ft-lbs (7 Nm) Assembly Notes • Never re-use lock nuts. Always replace with new parts. •...

  • Page 372: 2011 Progressive 121 Rear Mid Flap Covers

    Steering and Suspensions 2011 Progressive 121 Rear Mid Flap Covers CLOSEOFF FLAP UPPER FLAP UPPER FLAP PLATE 8.52...

  • Page 373: Progressive 136 Rail Assembly

    Steering and Suspensions Progressive 136 Rail Assembly INSIDE OF RAIL RAIL BUMPER SPACER SUPPORT PLATE TRACK TENSIONER BLOCK BUMPER LINER BOGIE WHEEL ASM. RAIL TIP BOGIE WHEEL MOUNT RAIL SLIDER METRIC FASTENERS A: 7.4 ft-lbs (10 Nm) B: 4 ft-lbs (5.4 Nm) C: Torque nut until screw protrudes 5mm...

  • Page 374: Progressive 136 Rail Fastener Locations

    Steering and Suspensions Progressive 136 Rail Fastener Locations LEFT RAIL SHOWN Components/Fasteners: • A - Rail Tip • B - Limiter Strap Shaft • C - Rail Bumper • D - Left Rail Front Holes - Bogie Wheel Asm. (Mount to outside of rail) •...

  • Page 375: Progressive 136 Front Torque Arm

    Steering and Suspensions Progressive 136 Front Torque Arm FRONT TRACK SHOCK BUSHING BUSHING UPPER TORQUE ARM SHAFTS PIVOT SHAFT FRONT TORQUE ARM BUSHING LIMITER STRAPS LIMITER STRAP SPACER METRIC FASTENERS INSTALL STRAPS RUBBER SIDE OUT A: 17 ft-lbs (23 Nm) B: 60 ft-lbs (80 Nm) Apply Loctite®...

  • Page 376: Progressive 136 Idler Shafts

    Steering and Suspensions Progressive 136 Idler Shafts REAR IDLER WHEELS WASHER ADJUSTER SPACER INNER SHAFT SPACER INSTALL TORQUE ARM BOLT IN THIS DIRECTION ADJUSTER SPACER SHAFT SHAFT SHAFT INNER SHAFT SPACERS WASHERS ANODIZED SHAFT METRIC FASTENERS A: 33 ft-lbs (45 Nm) Apply Loctite® 262™ to threads B: 50 ft-lbs (67 Nm) Apply Loctite®...

  • Page 377: Progressive 136 Rear Crank/Rear Scissor Assembly

    Steering and Suspensions Progressive 136 Rear Crank/Rear Scissor Assembly CRANK BUSHINGS REAR CRANK CRANK BUSHINGS PIVOT BUSHINGS BUSHING PLUG CRANK BUSHINGS BUSHING SPACER PIVOT BUSHINGS WASHER UPPER CARRIER WHEEL ASM. WASHER SPACER REAR PIVOT BUSHING PIVOT SHAFTS BUSHING WASHERS METRIC FASTENERS •...
  • Page 378 Steering and Suspensions 2012-2013 Progressive 121/136 Bumper/Closeoff Assembly REAR FLAP MID FLAP MID FLAP COOLER REAR BUMPER REAR PIVOT METRIC FASTENERS A: 33 ft-lbs (44.7 Nm) B: 3.6 ft-lbs (5 Nm) C: 9.5 ft-lbs (7 Nm) Assembly Notes • Never re-use lock nuts. Always replace with new parts. •...

  • Page 379: 2012-2013 Progressive 121/136 Rear Mid Flap Covers

    Steering and Suspensions 2012-2013 Progressive 121/136 Rear Mid Flap Covers CLOSEOFF FLAP UPPER FLAP UPPER FLAP PLATE 8.59...

  • Page 380: Rmk 144/Switchback Assault Pivots/Rear Idler

    Steering and Suspensions RMK 144/Switchback Assault Pivots/Rear Idler WASHER SPACER REAR IDLER WHEEL INNER SHAFT SPACER RMK REAR IDLERS REAR PIVOT INNER SHAFT INNER SHAFT REAR TRACK SHOCK PIVOT WASHERS SPACERS INNER SHAFT SHAFT STANDARD FASTENERS A: 35 ft-lbs (47.4 Nm) B: 35 ft-lbs (47.4 Nm) Apply Loctite®...

  • Page 381: Rmk144/Switchback Assault Rail Assembly

    Steering and Suspensions RMK144/Switchback Assault Rail Assembly TENSIONER BLOCK JAM NUT INSIDE OF RAIL RAIL BUMPER RMK 144 ONLY SWITCHBACK ASSAULT ONLY RAIL BUMPER RAIL BRACE BUMPER INSERT SPRING GUIDE RAIL TIP BOGIE WHEEL MOUNT BOGIE WHEEL ASM. RAIL SLIDER DOMED WASHER STANDARD FASTENERS A: 3-6 ft-lbs (4-8 Nm)...

  • Page 382: Rmk 144/Switchback Assault Rail Fastener Locations

    Steering and Suspensions RMK 144/Switchback Assault Rail Fastener Locations LEFT RAIL SHOWN Components/Fasteners: • A - Rail Tip • B - Limiter Strap Shaft • C - Rail Bumper • D - Bogie Wheel Asm. (Mount to outside of rail). •...

  • Page 383: Rmk 144/Switchback Assault Front/Rear Torque Arm

    Steering and Suspensions RMK 144/Switchback Assault Front/Rear Torque Arm FRONT TORQUE ARM PIVOT SHAFT INNER SHAFT INNER SHAFT BUSHING REAR PIVOT LIMITER STRAP INSTALL STRAPS RUBBER SIDE OUT BUSHINGS CARRIER WHEEL LIMITER STRAP SLEEVES 2012-2013 SWITCHBACK ASSAULT ONLY BUSHING SPRING ADJUSTER COLLAR SHOCK ROD TORSION SPRING...
  • Page 384 Steering and Suspensions 2011-2013 RMK/2011-2012 PRO RMK 155/163 Pivots/Rear Idler IDLER SPACER WASHER IDLER WHEEL SPACER WASHER WASHER REAR PIVOT INNER SHAFT IDLER SPACER BRACE SHAFT WASHER INNER SHAFT RMK ASSAULT ONLY SPACERS (FLAT SIDE UP) WASHERS SHOCK SHAFT LIMITER STRAP SHAFT METRIC FASTENERS •...

  • Page 385: 2013 Pro Rmk 155/163 Pivots/Rear Idler

    Steering and Suspensions 2013 PRO RMK 155/163 Pivots/Rear Idler WASHER IDLER WHEEL SPACER IDLER SPACER WASHER WASHER INNER SHAFT BRACE SHAFT IDLER SPACER REAR PIVOT WASHER WASHERS INNER SHAFT SHOCK SHAFT LIMITER STRAP SHAFT WASHER WAVE WASHER INSIDE SPACER (37.6MM) OUTSIDE SPACER (41MM) FRONT TRACK SHOCK METRIC FASTENERS...

  • Page 386: Rmk/Pro Rmk 155/163 Rail Assembly

    Steering and Suspensions RMK/PRO RMK 155/163 Rail Assembly ADJUSTER BLOCK JAM NUT ADJUSTER SCREW BUMPER BUMPER LINER INSIDE OF RAIL BUMPER BUMPER LINER SCRATCHER ASM. OPTION FOR 800 RMK RAIL TIP RAIL SLIDER BOGIE WHEEL MOUNT BOGIE WHEEL DOMED WASHER METRIC FASTENERS •...

  • Page 387: Rmk/Pro Ride Rmk 155/163 Rail Fastener Locations

    Steering and Suspensions RMK/PRO Ride RMK 155/163 Rail Fastener Locations LEFT RAIL SHOWN NOTE: 163 Rail Shown. 155/155 Assault Similar Components/Fasteners: • A - Rail Tip • B - Limiter Strap Shaft • C - Rail Bumper • D - Bogie Wheel Asm. (Mount to outside of rail) •...

  • Page 388: Rmk/Pro Rmk 155/163 Front Torque Arm

    Steering and Suspensions RMK/PRO RMK 155/163 Front Torque Arm FRONT TRACK SHOCK BUSHING REAR TRACK SHOCK FRONT PIVOT BUSHING GREASE ZERKS BUSHING FRONT TORQUE ARM GREASE ZERK PIVOT SHAFT PIVOT SHAFT LIMITER STRAP RMK ASSAULT ONLY BUSHING INSTALL STRAPS RUBBER SIDE OUT METRIC FASTENERS •...

  • Page 389: Rmk/Pro Rmk 155/163 Rear Torque Arm

    Steering and Suspensions RMK/PRO RMK 155/163 Rear Torque Arm BUSHING INNER SHAFT COLLAR GREASE ZERK BUSHING CARRIER WHEEL GREASE ZERK GREASE ZERK REAR PIVOT PIVOT SHAFT BUSHING BUSHING SHOCK ROD BUSHING GREASE ZERK REAR TRACK SHOCK PIVOT METRIC FASTENERS • All pivots must rotate freely after tightening fasteners.

  • Page 390: Pro-Ride Progressive Suspension Operation

    • IFS shock spring preload rider’s weight in everyday clothing, not riding gear. 2. Using the spring gauge tool supplied with the vehicle, Unlike other Polaris rear suspensions, the Pro-Ride set the spring preload. progressive rear suspension is not coupled and does not NOTE: Lifting up on the seat support will remove the feature front or rear-rear scissor stops.
  • Page 391 Steering and Suspensions 2010-2011 RTS Spring Guide All of the springs, spring gauge tools, and spring preload measurements using a tape measure are provided in the The stock rear track spring is a 190#/inch spring. The RTS Spring Guide Table below. stock spring will accommodate most riders weighing between 120 and 250 lbs.
  • Page 392 Steering and Suspensions 2012-2013 RTS Spring Guide All of the springs, spring gauge tools, and spring preload measurements using a tape measure are provided in the The stock spring will accommodate most riders weighing RTS Spring Guide Table below. between 120 and 260 lbs. (54-118 kg). NOTE: Use a tape measure in the same manner as a Two additional accessory springs are available for riders gauge tool with the end of the tape against the...
  • Page 393 Steering and Suspensions STEP 2 - FINE TUNE THE BALANCE For example, riders wanting less inside ski lift during cornering, but maximum traction during acceleration can RIDER ACTIVE shift their body position/weight towards the front and into the turn and then shift their body position/weight rearward SPRING PRELOAD when exiting and accelerating out of the turn.

  • Page 394: Rear Track Shock Thrust Bearing

    Steering and Suspensions NOTE: Use the compression dampeners to control The thrust bearing can be installed on 2010 models suspension bottoming, not the spring preload (equipped with original Walker Evans Shocks) by installing adjusters. the following parts: • Spring Retainer - 5137540 Turning the compression adjuster knobs clockwise will •...

  • Page 395: Progressive Rear Suspension Removal And Installation

    Steering and Suspensions PROGRESSIVE REAR SUSPENSION 6. Remove the upper carrier wheel assembly from the rear crank. REMOVAL AND INSTALLATION Removal 1. Place a large mat, shop blanket, or piece of cardboard on the floor next to the snowmobile. The piece should be large enough to protect the plastics when the unit is laid on its side.

  • Page 396: Rear Crank Service

    Steering and Suspensions 9. Locate and remove the two fasteners and threaded 6. Fold the rear scissor forward, and then work the rear pivot shafts securing the front torque arm to the of the skid into the track. tunnel. 7. Once the suspension is installed in the track, work the 10.

  • Page 397: Rear Track Shock Service

    Steering and Suspensions Rear Track Shock Service 8. Assembly is the reverse of removal. Torque fasteners to specification using new lock nuts. 1. Raise the snowmobile off the ground with a snowmobile lift. NOTE: Lifting at the bumper will compress the RTS. 2.

  • Page 398: Rmk Coil-Over Rear Suspension

    Steering and Suspensions RMK COIL-OVER REAR SUSPENSION All RMK coil-over rear suspensions are manufactured with STANDARD rear track shock springs that will accommodate rider weights (with gear) up to Suspension Adjustments 340 lbs. (154kg). The primary tuning component on all RMK coil-over rear suspensions is the rear track shock spring installed length.

  • Page 399: Heavy Duty Rear Track Shock Spring-Rmk Coil-Over

    Steering and Suspensions Heavy Duty Rear Track Shock Spring-RMK The part number for the HD spring is 7043741-067. Coil-Over Reference the RTSS Setup-Heavy Duty Spring Table below. An optional HEAVY DUTY spring is available if adjustments to the factory-installed springs are not sufficient for riders over 300 lbs.

  • Page 400: Fine Tuning Adjustments

    Steering and Suspensions Fine Tuning Adjustments Shock Dampening Additional minor adjustments can be made to the spring Compression damping adjustments can be made on 800 length to adjust the feel of the vehicle. Do not exceed the RMK and 800 RMK Assault models to control ride quality minimum and maximum installed length requirements.

  • Page 401: Rail Sliders

    Steering and Suspensions RAIL SLIDERS Wear Limit Replace sliders when wear exceeds notch. If sliders look “wavy” in appearance, check and adjust track tension or consider adding more bogie wheels. Removal/Installation 1. Raise the snowmobile off the ground using a snowmobile lift.
  • Page 402 Steering and Suspensions NOTES 8.82...
  • Page 403 Chassis CHAPTER 9 Chassis SAFETY INFORMATION ..........9.2 GENERAL CAUTIONS AND NOTES .

  • Page 404: Safety Information

    Chassis SAFETY INFORMATION Lord 406 Acrylic Adhesive Information Review and understand the following product handling General Cautions and Notes practices and first aid measures prior to working with • Never re-use lock Nuts. Always replace lock nuts bonding adhesive. that have been removed with new parts. •...

  • Page 405: Specifications

    Chassis SPECIFICATIONS COMPONENT TORQUE Fastener Torque Specifications Front footrest tube/rear 22 ft-lbs (30 Nm) over structure fasteners Running board support-to- COMPONENT TORQUE 26 ft-lbs (35 Nm) rear support braces Rear hood-to-rear over 7.4 ft-lbs (10 Nm) Rear support brace tunnel structure screws 26 ft-lbs (35 Nm) fasteners...

  • Page 406: Chassis Assemblies

    Chassis CHASSIS ASSEMBLIES Hood INSTRUMENT CLUSTER GASKET IGNITION SWITCH 2012-CURRENT BRAKE DUCT MESH SCREEN FILTER 2010-2011 BRAKE DUCT FILTER BRACKET AIRBOX SCREENS Front BELT/BELT HOLDER A: 7.4 ft-lbs (10 Nm) B: 3 ft-lbs (4 Nm) (Airbox/Headlight Asm. Screws) If the brake duct mounting posts break on a 2010-2011 Rush or Switchback Assault hood, install the Brake Duct Kit, PN 2204584.

  • Page 407: Left/Right Doors And Fenders

    Chassis Left/Right Doors and Fenders 1/4 TURN STUD 1/4 TURN RETAINER SIDE PANEL SCREEN RIGHT DOOR 1/4 TURN STUD 1/4 TURN CLIP RIGHT FENDER SIDE PANEL SCREEN 1/4 TURN CLIP LEFT DOOR EXHAUST SEAL SNOW DEFLECTOR 1/4 TURN CLIP Front RUBBER STRAP 1/4 TURN CLIP LEFT FENDER...

  • Page 408: Nosepan - Rush /Switchback

    Chassis Nosepan - Rush /Switchback NOSEPAN AIR DAM PLATE Front Bumper- Rush/Switchback HEAT EXCHANGER BRACKET FRONT BUMPER A: 7.4 ft-lbs (10 Nm)

  • Page 409: Front Bumper/Nosepan - Indy / Switchback Assault / Rmk

    Chassis Front Bumper/Nosepan - INDY / Switchback Assault / RMK BUMPER PLUG FRONT BUMPER LOWER FRONT BUMPER FIBER PAD NOSEPAN A: 7.4 ft-lbs (10 Nm)

  • Page 410: Seat/Seat Support - Rush Models

    Chassis Seat/Seat Support - RUSH Models SEAT SEAT SUPPORT X BRACE LE SUPPORT A: 7.4 ft-lbs (10 Nm) B: 17 ft-lbs (23 Nm)

  • Page 411: Seat/Seat Support - Switchback Models

    Chassis Seat/Seat Support - Switchback Models SEAT SEAT SUPPORT A: 7.4 ft-lbs (10 Nm) B: 17 ft-lbs (23 Nm)

  • Page 412: Seat/Seat Support - Switchback Adventure

    Chassis Seat/Seat Support - Switchback Adventure RACK LINER SEAT SUPPORT SEAT A: 7.4 ft-lbs (10 Nm) B: 17 ft-lbs (23 Nm) 9.10...

  • Page 413: Seat/Seat Support - Indy / Switchback Assault / Rmk

    Chassis Seat/Seat Support - INDY / Switchback Assault / RMK SEAT SEAT SUPPORT WASHERS A: 7.4 ft-lbs (10 Nm) 9.11...

  • Page 414: Front/Rear Over Structure/X Brace - Rush Models

    Chassis Front/Rear Over Structure/X Brace - RUSH Models ROPE GUIDE X BRACE REAR OVER STRUCTURE TUBE SPACER FRONT OVER STRUCTURE FOAM PADS 2011-CURRENT MODELS = HEX SCREWS A: 35 ft-lbs (47 Nm) B: 17 ft-lbs (23 Nm) C: 7 ft-lbs (9.5 Nm) D: 22 ft-lbs (30 Nm) CAUTION Front and rear over structure assemblies feature bonded...

  • Page 415: Front/Rear Over Structure/X Brace - Switchback Models

    Chassis Front/Rear Over Structure/X Brace - Switchback Models REAR OVER STRUCTURE ROPE GUIDE X BRACE TUBE SPACER FRONT OVER STRUCTURE FOAM PADS 2011-CURRENT MODELS = HEX SCREWS A: 35 ft-lbs (47 Nm) B: 17 ft-lbs (23 Nm) C: 7 ft-lbs (9.5 Nm) D: 22 ft-lbs (30 Nm) CAUTION Front and rear over structure assemblies feature bonded...
  • Page 416 Chassis Front / Rear Over Structure - 2011-2012 RMK Models / 2011-2013 Switchback Assault FOOT REST CLUTCH GUARD FOOT REST REAR OVER STRUCTURE TUBE SPACER TPS GUARD STUD PLATE WASHERS STUD PLATE RUNNING BOARD SUPPORT FRONT OVER STRUCTURE A: 7 ft-lbs (9.5 Nm) B: 22 ft-lbs (30 Nm) CAUTION Front and rear over structure assemblies feature bonded...

  • Page 417: Front / Rear Over Structure - 2013 Rmk 155/163 Models

    Chassis Front / Rear Over Structure - 2013 RMK 155/163 Models REAR OVER STRUCTURE TUBE SPACER SEE NOTE STUD PLATE FOOTREST FRONT OVER STRUCTURE POWERTRAC™ RUNNING BOARD FOOTREST TPS GUARD CLUTCH GUARD CLUTCH GUARD MOUNT A: 9 ft-lbs (12 Nm) B: 22 ft-lbs (30 Nm) C: 7 ft-lbs (9 Nm) CAUTION...

  • Page 418: Front Over Structure - Indy Models

    Chassis Front Over Structure - INDY Models REAR OVER STRUCTURE TUBE SPACERS STUD PLATE FRONT OVER STRUCTURE RUNNING BOARD SUPPORT/ROLL GRIP A: 22 ft-lbs (30 Nm) CAUTION Front and rear over structure assemblies feature bonded components. Do not attempt to service over structure tubes.

  • Page 419: Footrest Supports / Clutch Guard - Indy Models

    Chassis Footrest Supports / Clutch Guard - INDY Models TUBE SPACER FOOTREST TUBE FOOTREST BRACKET FOOTREST FOOTREST BRACKET FOOTREST TUBE TPS GUARD UPPER FOOTREST CLUTCH GUARD FOOTREST CLUTCH GUARD BRACKET A: 7 ft-lbs (9.5 Nm) B: 25 ft-lbs (35 Nm) CAUTION Front and rear over structure assemblies feature bonded components.

  • Page 420: Left/Right Bulkhead Clips/Side Braces-All Models

    Chassis Left/Right Bulkhead Clips/Side Braces-All Models EXHAUST SILENCER BRACKET (DC-CFI-2 MODELS ONLY) EXHAUST SILENCER BRACKET RIGHT SIDE PLATE* BULKHEAD FLOOR PLATE* CROSS BRACE RIGHT BULKHEAD CLIP* REAR PTO ENGINE MOUNT A-ARM STUDS FRONT PTO ENGINE MOUNT (PLATE/ENGINE MOUNT SCREWS) LEFT SIDE PLATE* LEFT BULKHEAD CLIP* (PLATE/ENGINE MOUNT SCREWS) A: 35 ft-lbs (47 Nm)

  • Page 421: Tunnel Rear - Indy Models

    Chassis Tunnel Rear - INDY Models SNOW FLAP BRAKE LIGHT HOUSING RUNNING BOARD CLOSEOFF WIRE HARNESS CHANNEL BUMPER BUMPER PLUG A: 7 ft-lbs (9.5 Nm) 9.19...

  • Page 422: Tunnel Rear - Rush Models

    Chassis Tunnel Rear - RUSH Models RUNNING BOARD SUPPORT RUNNING BOARD CLOSEOFF REAR SUPPORT BRACES TUNNEL GRIPPER RUNNING BOARD CLOSEOFF TUNNEL GRIPPER A: 26 ft-lbs (35 Nm) CAUTION Running board supports feature bonded components. Do not attempt to service supports. 9.20...

  • Page 423: Tunnel Rear - Switchback

    Chassis Tunnel Rear - Switchback RUNNING BOARD SUPPORT RUNNING BOARD CLOSEOFF REAR SUPPORT BRACES RUNNING BOARD CLOSEOFF TUNNEL GRIPPER TUNNEL GRIPPER A: 26 ft-lbs (35 Nm) CAUTION Running board supports feature bonded components. Do not attempt to service supports. 9.21...

  • Page 424: Tunnel Rear - Switchback Assault / Rmk

    Chassis Tunnel Rear - Switchback Assault / RMK BUMPER SUPPORT BUMPER TUBE BRAKE LIGHT COVER PLUG BRAKE LIGHT WIRE CHANNEL SNOW FLAP CLOSEOFF A: 7 ft-lbs (9.5 Nm) 9.22...

  • Page 425: Left/Right Foot Supports - Rush / Switchback Models

    Chassis Left/Right Foot Supports - RUSH / Switchback Models RH UPPER FOOTREST FOOTREST TUBE REAR OVER STRUCTURE RH LOWER FOOTREST LH UPPER FOOTREST FOOTREST TUBE Front CLUTCH GUARD LH LOWER FOOTREST TPS GUARD After removing the rear over structure, the rivets securing the upper footrest panels to the tubes can be drilled out.

  • Page 426: Switchback Adventure Saddle Bags

    Chassis Switchback Adventure Saddle Bags RUBBER STRAPS SADDLE BAG LID LOCK N’ RIDE ANCHOR LOCK N’ RIDE ANCHOR RETAINER CABLE SADDLE BAG LID HINGE BAG SUPPORT BRACKET LOCK N’ RIDE ANCHOR Retainer Cable Fasteners: 3 ft-lbs (4 Nm) Lid Hinge Fasteners: 7.3 ft-lbs (10 Nm) CAUTION Running board supports feature bonded components.

  • Page 427: Bonded Component Service

    Chassis BONDED COMPONENT SERVICE Bonded Component Surface Preparation Overview WARNING The following serviceable components are bonded with structural adhesive: Handling Practices Ventilation - Work in a well-ventilated area. • Left/right bulkhead clips are bonded to the left/right support braces Respirator - Use properly-fitted, organic vapor, air •...

  • Page 428: Adhesive Applicator Kits

    Chassis Adhesive Applicator Kits Obtaining Adhesive/Mixing Tools Commercially • The only Polaris-authorized adhesive is Lord 406/ Polaris offers a repair kit, individual adhesive cartridges, 19 Acrylic Adhesive (Lord 50mL PN:3003680). and replacement needle packs. The adhesive has a shelf Do not use Lord Fusor® Adhesive.

  • Page 429: Adhesive Application Patterns

    Chassis Adhesive Application Patterns 3. While holding the mixer needle over a piece of scrap material, slowly compress the caulk gun trigger to fill Reference the following illustrations showing the exact the mixer needle. The needle will automatically mix patterns for each bonded component when applying the and dispense the correct volumetric ratio of adhesive adhesive.
  • Page 430 Chassis RH (MAG) SIDE BRACE Chaincase (2012-Later Models) (MATING SURFACE) (BULKHEAD MATING SURFACE) ADHESIVE LINE ADHESIVE LINE APPLY ADHESIVE TO COOLER/PLATE MATING SURFACE (FRONT CLIP MATING SURFACE) ADHESIVE LINE ADHESIVE APPLY SMALL AMOUNT OF ADHESIVE HERE LINE NOTE: Adhesive application can be used on 2010- 2011 models.

  • Page 431: Bulkhead Floor Plate Removal

    Chassis Bulkhead Floor Plate Removal NOTE: Allow the adhesive to cure for 24 hours at 68° F (20° C) before placing the snowmobile back into 1. Follow the procedures for removing the engine. See service. Engine chapter. 2. Remove the fender from the chassis on the side of the Front Tunnel Bulkhead Cooler Removal vehicle that requires service.

  • Page 432: Front Tunnel Bulkhead Cooler Installation

    Chassis 6. Remove any residual adhesive from the tunnel and/ 8. Reinstall the following components: or cooler if it is going to be re-used. • Right/left engine compartment door • Hood Front Tunnel Bulkhead Cooler Installation • Exhaust pipe/silencer 1. If installing the original bulkhead cooler, verify all of •...

  • Page 433: Left Bulkhead Clip Removal

    Chassis Left Bulkhead Clip Removal 1. Remove the following components: • Right/left engine compartment door • Hood • Nosepan/bumper • Exhaust pipe/silencer • Oil tank/clutch cover assembly • Airbox assembly • Engine assembly • Left-side front engine mount • Bulkhead floor plate •...
  • Page 434 Chassis 6. Remove the screws securing the over structure to the 9. Wearing heat resistant gloves, use a propane gas bulk head clip. torch to heat the adhesive between the two components. Apply torch until adhesive begins to crackle. During this time, the adhesive may smoke and bubble....

  • Page 435: Left Bulkhead Clip Installation

    Chassis Left Bulkhead Clip Installation 7. Reinstall the bulkhead clip fasteners including lower heat exchanger mount screw/nut. Torque nuts to 1. Verify the bulkhead clip and engine side support specification. brace are thoroughly cleaned and all residual adhesive is removed from both parts. 2.

  • Page 436: Right Bulkhead Clip Removal

    Chassis Right Bulkhead Clip Removal 10. Reinstall the lower steering shaft nut. Torque nut to specification. 1. Remove the following components: • Right/left engine compartment door • Hood • Nosepan/bumper • Exhaust pipe/silencer • Exhaust silencer bracket • Oil tank/clutch cover assembly •...
  • Page 437 Chassis 5. Remove the bulkhead clip fasteners/nuts. 6. Remove the cross shaft fastener from the bulk head clip. LOWER HEAT EXCHANGER MOUNT 7. Remove the screws securing the over structure to the bulk head clip. 9.35...
  • Page 438 Chassis 8. Remove the tie rod boot. Remove the idler arm bolt NOTE: Left side shown. and nut. PROPANE GAS TORCH CAUTION 9. When all of the noted fasteners and nuts are removed, the next step is to heat where the bulkhead clip mates with the engine side support brace.

  • Page 439: Right Bulkhead Clip Installation

    Chassis 11. Once the adhesive bond is broken, remove the right- 6. Torque fasteners to specification. side bulkhead clip from the chassis. Note the old (residual) adhesive. If the component is to be re-used, the adhesive must be completely removed. See Bonded Component Surface Preparation section.
  • Page 440 Chassis 8. Reinstall the over structure-to-bulkhead screws. 10. Reinstall the idler arm bolt and nut. Torque nut to Torque screws to specification. specification. Idler Arm Nut: 37 ft-lbs (50 Nm) 11. Reinstall the tie rod boot. 12. Reinstall the bulkhead floor plate. 13.

  • Page 441: Left Support Brace Removal

    Chassis Left Support Brace Removal 5. Wearing heat resistant gloves, use a propane gas torch to heat the where the brace mounts to the tunnel 1. Remove the following components: and bulkhead clip. Apply torch until adhesive begins to crackle. During •...

  • Page 442: Left Support Brace Installation

    Chassis Left Support Brace Installation NOTE: Allow the adhesive to cure for 24 hours at 68° F (20° C) before placing the snowmobile back into 1. Verify the bulkhead clip, side brace, and tunnel are service. thoroughly cleaned and all residual adhesive is removed from the parts.
  • Page 443 Chassis 5. Remove the four remaining brace screws and nuts. 8. Note the residual adhesive on the brace, bulkhead clip Note the screw located on the inside of the brace and tunnel. If the component is to be re-used, the attaching the brace to the bulkhead cooler.

  • Page 444: Right Support Brace Installation

    Chassis Right Support Brace Installation 1. Verify the bulkhead clip, side brace, and tunnel are thoroughly cleaned and all residual adhesive is Bulkhead Clip-to-Brace Fasteners: 26 ft-lbs (35 Nm) removed from the parts. Brace-to-Tunnel Fasteners: 26 ft-lbs (35 Nm) 2. Gather together the T40 screws and nuts, and Exhaust Bracket Fasteners: 26 ft-lbs (35 Nm) exhaust silencer bracket and nuts.
  • Page 445 Battery and Electrical Systems CHAPTER 10 Battery and Electrical SPECIFICATIONS ............10.3 ENGINE MODELS.
  • Page 446 Battery and Electrical Systems DC-CFI ELECTRICAL SYSTEMS ......... 10.28 DC-CFI STATOR ASSEMBLY .

  • Page 447: Specifications

    Battery and Electrical Systems SPECIFICATIONS WARNING Engine Models PROPOSITION 65 WARNING BATTERY POSTS TERMINALS AND RELATED ACCESSORIES Model Number Engine CONTAIN LEAD AND LEAD COMPOUNDS CHEMICALS KNOWN S4202-6044-OP6N TO THE STATE OF CALIFORNIA TO CAUSE CANCER AND RE Domestic L/C 600cc S4215-6044-OO6N...

  • Page 448: Digital Instrument Cluster

    Battery and Electrical Systems DIGITAL INSTRUMENT CLUSTER Overview ENGINE RPM/VEHICLE SPEED HIGH BEAM CK. ENGINE MIL ENGINE TEMP. BRAKE OIL LEVEL LOW PERC RVS PERFORMANCE DISPLAY SELECT FUEL LEVEL MODE VEHICLE INFO. DISPLAY Information regarding vehicle speed, engine RPM, engine overheat, PERC, oil level, brake, engine temperature (2011-current models) and check engine MIL (diagnostic trouble codes) is transmitted to the gauge from the ECU...

  • Page 449: Rider Information Display

    Battery and Electrical Systems Rider Information Display 11. Reverse Indicator - Icon will illuminate and flash whenever PERC reverse mode button is pushed on The rider information display is located in the instrument the LH control. cluster. All segments will illuminate for approximately one second at start-up.

  • Page 450: Performance Information Area

    Battery and Electrical Systems Performance Information Area Diagnostic Display The performance information area (middle) of the display The instrument cluster can display diagnostic trouble screen is dedicated to displaying: codes (DTCs) when, and only when, the check engine MIL is illuminated. •...

  • Page 451: Fuel Select Mode

    Battery and Electrical Systems Fuel Select Mode 2013 models utilize the instrument cluster to select fuel modes. 1. Start the engine. 2. Lock the parking brake. 3. Press and release the “SEL” button on the gauge or the “SET” button on the left hand control until either “Eth”...

  • Page 452: Analog/Digital Instrument Cluster

    Battery and Electrical Systems ANALOG/DIGITAL INSTRUMENT CLUSTER Overview SPEEDOMETER INDICATOR LAMPS MODE BUTTON RIDER INFORMATION CENTER Information regarding vehicle speed, engine RPM, engine overheat, PERC, oil level, brake, engine temperature and check engine MIL (diagnostic trouble codes) is transmitted to the gauge from the ECU using CAN BUS communication technology.

  • Page 453: Rider Information Display

    Battery and Electrical Systems Rider Information Display •Parking Brake Indicator - Icon will illuminate whenever the brake lever is The rider information display is located in the instrument pulled or when the parking brake is cluster. All segments will illuminate for approximately one engaged.

  • Page 454: Changing Units

    Battery and Electrical Systems Changing Units Analog/Digital IC Error Code Display The instrument cluster will display either standard or Active diagnostic trouble codes can be reviewed by metric units. Change between the two by following these accessing the instrument cluster’s diagnostic display steps: mode.

  • Page 455: Security System

    An optional security feature is available on all 2012 and later Pro-Ride snowmobiles which is enabled by an authorized Polaris dealer using Digital Wrench®. The security feature allows the operator to lock the ECU to prevent unauthorized use. When security is locked the ECU will prevent clutch engagement by limiting engine speed to 3500 RPM.
  • Page 456 Battery and Electrical Systems 3. Start Digital Wrench® on the PC/laptop. Navigate to 6. If the security function is not enabled, the following the appropriate vehicle home page. Select OPTION screen will appear. Highlight the entire REQUEST 6 - SECURITY FUNCTIONS from the Special Tests code and then copy it by pressing (CTRL+C).

  • Page 457: Security System: Digital Wrench® Disable

    Battery and Electrical Systems Security System: Digital Wrench® Disable 9. Digital Wrench® will begin to reflash the ECU. A timer and status indicator bar on the screen will indicate the The security system can be disabled by turning off the process is working.

  • Page 458: Security System: Digital Wrench® Pass Code Reset

    Battery and Electrical Systems Security System: Digital Wrench® Pass code 3. Start Digital Wrench® on the PC/laptop. Navigate to Reset the appropriate vehicle home page. Select OPTION 5 - SECURITY FUNCTIONS from the Special Tests If the three digit pass code is either lost or unknown, it can (Red Toolbox) Menu.

  • Page 459: Security System: Instrument Cluster Initialization

    Battery and Electrical Systems 6. After the reset passcode process is complete, the 2. Connect the dual power-up adapter to the chassis following screen will be displayed. Click on the power-up harness. Attach one of the dual power-up RETURN button to return to the main screen. connectors to the ECM PWR plug and the other connector to the DC PWR TEST plug.
  • Page 460 Battery and Electrical Systems 4. Wait until ENTER CODE displays, and then press and 5. SECURE ON will be displayed. The display will release MODE button 3 consecutive times to enter alternate between SECURE ON and ENTER CODE. and accept the 000 base code. NOTE: If the ENTER CODE screen exits due to inactivity, repeat step 3.

  • Page 461: Security System: Locking

    Battery and Electrical Systems Security System: Locking 7. SECURE OFF displays if the system unlocks. NOTE: Use the MODE button on the cluster when performing procedure on models featuring the analog/digital instrument cluster. 1. Start the engine in a well-ventilated area. 2.

  • Page 462: Security System: Unlocking

    Battery and Electrical Systems 5. After pressing MODE to accept the last digit, view the Security System: Unlocking display screen. SECURE ON displays if the system NOTE: Use the MODE button on the cluster when locks. Engine RPM speed is now limited and the performing procedure on models featuring the snowmobile cannot be driven.

  • Page 463: Security System: Changing Pass Code

    NOTE: Use the MODE button on the cluster when • Security system activation requires an authorized performing procedure on models featuring the Polaris dealer using Digital Wrench® to turn on the analog/digital instrument cluster. function in the ECU. • First time use requires an initialization procedure...

  • Page 464: Maintenance-Free Battery

    Battery and Electrical Systems MAINTENANCE-FREE BATTERY 4. Remove the rubber strap. Disconnect the BLACK(-) cable first, and then the POSITIVE(+) cable. Specifications 5. Installation is the reverse of removal. Install the RED (+) cable first, and then the BLACK (-) cable during Battery PN 4012638 installation.

  • Page 465: Charging Procedure

    Battery and Electrical Systems Charging Procedure OCV - Open Circuit Voltage Test If battery voltage is 12.6 VDC or less, the battery may Battery voltage should be checked with a digital need recharging. When using an automatic charger, refer multimeter. Readings of 12.6 volts or less require further to the charger manufacturer’s instructions for recharging.

  • Page 466: Battery Conductance Analyzer

    NOTE: Battery charge can be maintained by using a Authorized Polaris dealers/distributors are required to Polaris battery tender charger or by charging once a use the conductance analyzer when testing 12V Polaris month to make up for normal self-discharge. Battery batteries.

  • Page 467: Electric Start

    Battery and Electrical Systems ELECTRIC START System Schematic DC- -CFI ECU CNA CONNECTOR DG/WH RED/BLK KEY SWITCH 10A BREAKER (CIRCUIT CLOSED WHEN KEY TURNED TO START) WHITE CHASSIS/ELECTRIC START HARNESS CONNECTOR WH/RD STARTER SOLENOID RD/DK STARTER MOTOR AC REGULATOR BATTERY CHARGE GROUND BATTERY BATTERY CHARGE...

  • Page 468: Starter Motor/Flex Drive Assembly

    Battery and Electrical Systems Starter Motor/Flex Drive Assembly STARTER MOTOR WORM GEAR CLAMP FLEX DRIVE PINION/PINION BRACKET END PLATE MOUNTING BRACKET 4. To remove the starter motor, remove the gear clamp, CAUTION and then the two-rear starter motor mount nuts. 5.

  • Page 469: Battery Box Assembly

    Battery and Electrical Systems Battery Box Assembly POSITIVE CABLE (SOLENOID TO STARTER MOTOR) POSITIVE CABLE (SOLENOID TO BATTERY) CIRCUIT BREAKER LEAD CIRCUIT BREAKER GROUND CABLE SOLENOID BATTERY HEAT SHEILD STRAP BATTERY BOX CAUTION Always disconnect BLACK (-) battery cable first, and then RED (+) cable.

  • Page 470: Ignition Timing

    Battery and Electrical Systems IGNITION TIMING 8. If the pointer is outside the variance, either the flywheel key has sheared allowing the flywheel to move on the crankshaft, the crankshaft is out of index, Timing Procedure a problem with the engine electrical harness exists, or NOTE: Before performing procedure, verify there are one of the crankshaft position sensors has moved.

  • Page 471: Ignition Timing Chart

    Battery and Electrical Systems Ignition Timing Chart BTDC to either inches or millimeters, then use a dial indicator to verify timing marks. Convert the ignition timing specification from degrees 600 DC-CFI-2/4 800 DC-CFI-2 ROD/STROKE (mm) 128mm ROD / 64mm STROKE 132mm ROD / 70mm STROKE Degrees BTDC Inches...

  • Page 472: Dc-Cfi Electrical Systems

    Battery and Electrical Systems DC-CFI ELECTRICAL SYSTEMS DC-CFI Stator Assembly DC-CFI Stator Specifications RESISTANCE ITEM COLOR SYSTEM FUNCTION +/- 15% @68 F (20 ° ° 14VAC Chassis Power - Battery Charge (Electric Start Equipped) YELLOW TO YELLOW = 0.12 AC Lighting Coil (Y) YELLOW to YELLOW - Head / Tail Lights...

  • Page 473: Dc Regulator/Rectifier

    Battery and Electrical Systems DC Regulator/Rectifier There are two generations of capacitors used on PRO- RIDE snowmobiles. The first generation is mounted on top of the DC regulator/rectifier located on the clutch cover. Second generation capacitors housed in a weather-tight pouch taped to the wiring harness located on the right over structure frame tube.

  • Page 474: Ignition Coil Packs

    Battery and Electrical Systems Combination AC/DC Regulator - Battery Ignition Coil Packs Charge Rectifier 2013 DC-CFI models feature a combination AC/DC regulator with battery charge rectifier. The module regulates all AC and DC power for the vehicle and rectifies power for all DC circuits and for charging the battery.

  • Page 475: Oil Level Sender

    Battery and Electrical Systems Oil Level Sender Auxiliary Stop Switch The auxiliary stop switch is a hard stop switch and will shut off the engine when pushed down. There are two switch types used on PRO-RIDE snowmobiles, but both types function the same. Type one switches are integrated into the right hand throttle block.

  • Page 476: Throttle Release Switch

    Throttle Release Switch PERC Switch The throttle release switch is integrated into the right There are two types of Polaris Electronic Reverse Control hand throttle control block. The switch provides a (PERC) switches used on PRO-RIDE snowmobiles, but software stop signal to the ECU.

  • Page 477: Dc-Cfi Regulated (Red) Power Circuits

    Battery and Electrical Systems DC-CFI Regulated (Red) Power Circuits DC- -CFI ECU 3 4 P I N CNA CONNECTOR 34 17 WH/DB BRN/YEL WHT/YEL DIGITAL WRENCH PLUG RED/WHT CHASSIS RELAY FUEL PUMP EV SOLENOID PRIME PLUG REGULATOR FUEL PUMP RECTIFIER EXT.

  • Page 478: Dc-Cfi Chassis (Red/White) Power Circuits

    Battery and Electrical Systems DC-CFI Chassis (Red/White) Power Circuits DC- -CFI ECU 3 4 P I N CNA CONNECTOR BN/WH INSTRUMENT CLUSTER RD/WH POWER RD/WH BN/WH BROWN DC POWER RD/WH TEST PLUG OR/BK 2 AMP FUSE ACCESSORY POWER RD/WH RD/YE PLUG BROWN ORANGE...

  • Page 479: Dc-Cfi Ac Power (Lighting) Circuits

    Battery and Electrical Systems DC-CFI AC Power (Lighting) Circuits INSTRUMENT CLUSTER YE/RD YE/RD HEAD LIGHTS YE/RD HAND WARMERS THUMB WARMER DG/YEL BLU/RED BLUE GRY/WHT ORG/GRN YELLOW DG/YEL BRN/WHT YE/RD BRN/WHT AC REGULATOR POWER RECTIFIER TEST BATTERY VOLTAGE RED/GRN AC STATOR VOLTAGE YELLOW GROUND BROWN...

  • Page 480: Dc-Cfi Throttle/Ignition Disable System

    Battery and Electrical Systems DC-CFI Throttle/Ignition Disable System DC- -CFI ECU CNA CONNECTOR BLACK IGNITION SWITCH (SWITCH CLOSED WHEN KEY TURNED TO OFF) BLK/RED TETHER SWITCH (CLOSED WHEN TETHER REMOVED) OPTIONAL 2148 THROTTLE LEVER SWITCH SAFETY SLAP SWITCH (PUSHED = CLOSED) 2148 OHMS = SWITCH CLOSED/LEVER REL.

  • Page 481: Diagnostic Plugs

    Battery and Electrical Systems DIAGNOSTIC PLUGS DC PWR Plug Connect the Chassis Power-Up Harness to the DC PWR Power Test Plugs plug to supply battery power to the following components: • Instrument cluster • DC accessory power points • LED tail lamp/brake lamp ECM PWR Plug FUEL PUMP PRIME Connect the Chassis Power-Up Harness to the ECM...

  • Page 482: Hand/Thumb Warmers

    Battery and Electrical Systems HAND/THUMB WARMERS MOLEX CONNECTOR Thumb Warmer Diagnostics The thumb warmer on all Polaris snowmobiles is a thermistor-type warming element pad. This means its resistance will change based on temperature. Thumb Warmer Resistance Checks RESISTANCE @ ROOM CIRCUIT (Wire Color) TEMP.

  • Page 483: Hand Warmer Diagnostics

    There are two types of hand warmer element pads used NOTE: Hand warmer pads do not feature a high on Polaris snowmobiles. One version is used on steel/ temperature circuit. On snowmobiles featuring a left- painted handlebars and touring model rear passenger...

  • Page 484: Full Length Hand Warmers

    Battery and Electrical Systems Full Length Hand Warmers Some models feature integrated handlebar hooks with full length hand warmer elements. These hand warmers differ from standard length warmers in that they are cut to match the bend of the integrated handlebar hooks. Because of this, there are separate warming elements for the left and right side of the handlebar assembly.
  • Page 485 2010 RUSH Chassis Harness 1 of 2...
  • Page 486 2010 600 RUSH Chassis 2 of 2...
  • Page 487 2010 RUSH Hood Harness...
  • Page 488 2010 RUSH Engine Harness...
  • Page 489 2011 PRO-RIDE 600 STD. Chassis Harness 1 of 2...
  • Page 490 2011 600 PRO-RIDE STD.Chassis Harness 2 of 2...
  • Page 491 2011 PRO-RIDE 800 STD. Chassis Harness 1 of 2...
  • Page 492 2011 PRO-RIDE 800 STD. Chassis Harness 2 of 2...
  • Page 493 2011 PRO-RIDE 800 Premium Chassis Harness 1 of 2...
  • Page 494 2011 PRO-RIDE 800 Premium Chassis Harness 2 of 2...
  • Page 495 2011 PRO-RIDE Hood Harness...
  • Page 496 2011 PRO-RIDE 600 4 Injector Engine Harness...
  • Page 497 2011 PRO-RIDE 800 2 Injector Engine Harness...
  • Page 498 2012 PRO-RIDE 600 STD. Chassis Harness 1 of 2...
  • Page 499 2012 600 STD.Chassis Harness 2 of 2...
  • Page 500 2012 PRO-RIDE 800 STD. Chassis Harness 1 of 2...
  • Page 501 2012 PRO-RIDE 800 STD. Chassis Harness 2 of 2...
  • Page 502 2012 PRO-RIDE 600/800 Premium Chassis Harness 1 of 2...
  • Page 503 2012 PRO-RIDE 600/800 Premium Chassis Harness 2 of 2...
  • Page 504 2012 PRO-RIDE Hood Harness...
  • Page 505 2012 PRO-RIDE 600 4 Injector Engine Harness...
  • Page 506 2012 PRO-RIDE 600/800 2 Injector Engine Harness...
  • Page 507 2013 PRO-RIDE STANDARD 1 of 2 EV SOLENOID (P/N 4011244) REGULATOR OIL LEVEL SWITCH TAILLIGHT TAILLIGHT FILE NAME: 2411810.RSD POWER/VOLTBOOST TAILLIGHT FUEL PUMP WIRE COLOR LEGEND BEIGE (TAN) FUEL PUMP PRIME JUMPER HARNESS E = ENGINE GROUND LH CONTROL SIGNAL LH CONTROL POWER BLACK LIGHT BLUE...
  • Page 508 2013 PRO-RIDE STANDARD 2 of 2 SCHEMATIC CABLE/WIRE TERMINATION TABLE INDEX CCT # TYPE GAUGE COLOR FROM COMPONENT FROM PORT TO COMPONENT TO PORT FUNCTION DG/WH ECM (CNA) CHASSIS/HOOD STARTER LOCKOUT RD/BK ECM (CNA) ELECTRIC START BATTERY VOLTAGE BK/DB ECM (CNA) CHASSIS SENSOR GND SPLICE #1 SENSOR GND DG/RD ECM (CNA)
  • Page 509 2013 PRO-RIDE PREMIUM 1 of 2 EV SOLENOID MODE/SET SWITCH HEADLIGHT SWITCH HANDWARMER SWITCH (P/N 4011244) REGULATOR OIL LEVEL SWITCH (P/N 4012090) (P/N 4012091) (P/N 4011319) (P/N 4012624) TAILLIGHT FILE NAME: 2411756.RSD TAILLIGHT WIRE COLOR LEGEND FUEL PUMP POWER/VOLTBOOST BEIGE (TAN) TAILLIGHT E = ENGINE GROUND FUEL PUMP PRIME...
  • Page 510 2013 PRO-RIDE PREMIUM SCHEMATIC CABLE/WIRE TERMINATION TABLE INDEX CCT # TYPE GAUGE COLOR FROM COMPONENT FROM PORT TO COMPONENT TO PORT FUNCTION 2 of 2 CIRCUIT DG/WH ECM (CNA) CHASSIS/HOOD STARTER LOCKOUT ES DC-SDI HARNESS BREAKER (P/N 2411513) AC PWR SPLICE HEATER SW ELECTRIC START RD/BK ECM (CNA)
  • Page 511 2013 INDY HOOD RECEPTACLE (P/N 4010638) 12V OUTLET HARNESS WIRE COLOR LEGEND (P/N 2411352) BEIGE (TAN) E = ENGINE GROUND BLACK LIGHT BLUE HEADLIGHT (P/N 2411017) ACC_PWR DARK BLUE C = CHASSIS GROUND BROWN GRAY LIGHT GREEN NC = SWITCH NORMALLY CLOSED DARK GREEN R HEADLIGHT L HEADLIGHT...
  • Page 512 2013 600/800 RUSH/SWITCHBACK/RMK HOOD WIRE COLOR LEGEND (P/N 4010638) BEIGE (TAN) RECEPTACLE E = ENGINE GROUND BLACK LIGHT BLUE DARK BLUE C = CHASSIS GROUND BROWN GRAY LIGHT GREEN NC = SWITCH NORMALLY CLOSED DARK GREEN ORANGE NO = SWITCH NORMALLY OPEN PINK CONNECTOR B HARNESS: 2411861-01...

This manual is also suitable for:

600 rush 2011800 rush 2011800 switchback assault 2011800 rmk 155 2011800 rmk assault 2011800 pro rmk 163 2011 ... Show all

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