User Manuals: Polaris 800 RUSH 2012 Snowmobile

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Polaris 800 RUSH 2012 Manual

Polaris 800 RUSH 2012 Manual (512 pages)

Brand: Polaris | Category: Snowmobiles | Size: 64 MB

Table of Contents

Table of Contents

1
- 2011 600 Rush
  4
- Chapter 1
  4
- 2011 800 Rush
  6
- 2011 800 Switchback Assault
  8
- 2012 600 Rush
  16
- 2012 800 Rush
  18
- 2012 600 Switchback
  22
- 2012 800 Switchback
  24
- 2012 Switchback Assault
  26
- 2012 800 Pro Rmk 155/163
  38
- 2013 600 Indy/Indy Sp
  40
- 2013 600 Rush
  42
- 2013 600 Switchback
  48
- 2013 800 Switchback
  50
- 2013 Switchback Assault
  52
- 2013 600 Rmk 144
  54
- 2013 600 Rmk 155
  56
- 2013 600 Pro Rmk 155
  58
- 2013 800 Pro Rmk 155/163
  64
- Snowmobile Number Designations
  66
- Vehicle Identification Number
  66
  - Vin Number Designation
    66
  - Tunnel Decal
    67
- Publication Part Numbers
  68
  - 2010 Publications
    68
- Special Tools
  70
- General Reference
  71
  - Standard Bolt Torque Specification
    71
  - Metric Bolt Torque Specification
    71
  - Gasoline Volatility
    72
  - Fuel / Oil Premix Ratios
    72
  - Fuel Recommendations
    72
  - Sae Tap Drill Sizes
    73
  - Metric Tap Drill Sizes
    73
  - Decimal Equivalents
    73
Chapter 2 Maintenance

75
- Periodic Maintenance
  77
- Maintenance Products
  79
  - Engine Oils / Lubricants / Misc
    79
- Break-In Procedures
  80
- Engine Maintenance
  80
  - Variable Exhaust Valve Cleaning
    80
  - Spark Plugs
    82
  - Spark Plug Caps/Spark Plug Terminals
    83
  - Spark Plug Wire Maintenance/Routing
    83
  - Surge Tank
    84
  - Recommended Coolant
    84
  - Cooling System Bleeding
    84
  - Engine Mount Bolt Re-Torque
    85
  - Oil Pump Adjustment
    86
  - Oil Pump Bleeding
    87
  - Oil Injection Hose Priming
    87
  - Oil Tank/Clutch Cover Service
    88
  - Oil Filter Service
    89
  - Oil Supply Hose Routing/Panduit Strap
    90
- Pvt System
  91
- Fuel/Intake System
  94
  - Fuel Filter - DC-Cfi-4 Models
    94
  - Fuel Filter - DC-Cfi-2 Models
    94
  - Fuel Hose Inspection
    96
  - Fuel Tank Vent System
    96
  - Fuel Tank Vent Hose Routing
    97
  - Air Box/Pre-Filters
    97
  - Air Box Servicing
    98
- Chassis
  99
  - Door/Hood Removal and Installation
    99
  - Chain Case Oil Level Check
    101
  - Chain Case Oil Replacement
    101
  - Drive Chain Tension Adjustment
    101
  - Chain Case Fastener Re-Torque
    102
  - Quickdrive™ Low Inertia System
    102
- Brake System Maintenance
  103
  - Brake Lever Travel
    103
  - Brake Fluid
    103
  - Brake Pad Replacement
    103
- Throttle Cable Adjustment
  103
  - Throttle Lever Free-Play
    103
  - Throttle Cable Routing
    104
- Steering / Suspension Maintenance
  104
  - Handlebars
    104
  - Adjustable Riser
    105
  - Ski/Ski Skag Fasteners
    105
  - Track Tension
    106
  - Track Alignment
    107
  - Suspension Pivots/Lubrication
    107
  - Suspension Lubrication
    108
- Electrical Systems
  109
  - Headlight Bulb Replacement
    109
  - Tail Lamp Replacement
    109
- Off-Season Storage
  110
  - Chassis and Hood
    110
  - Clutch and Drive System
    110
  - Controls and Linkage
    110
  - Electrical Connections
    110
  - Carburetor/Throttle Body
    110
  - Fuel System
    110
  - Corrosion
    110
  - Shocks
    110
  - Battery
    110
Chapter 3 Engine/Cooling/Exhaust

111
- Engine Specifications
  113
- Fastener Torque Guide
  113
- Component Torque Sequences
  114
- Engine Service Specifications - All Engines
  115
- Engine Specifications
  115
- Vehicle/Engine Matrix
  116
- Engine Inspections
  117
  - Cylinder Head Inspection
    117
  - Cylinder Measurement
    118
  - Piston Inspection
    119
  - Piston Ring Installed Gap
    119
  - Reed Valve Inspection
    120
  - Bearing Fit
    120
  - Crankshaft Runout Inspection
    121
  - Main Bearing
    121
  - Connecting Rod Lower Bearing
    121
  - Piston Needle Bearing
    122
  - Crankshaft Index
    123
  - Checking Crankshaft Index
    123
  - Cylinder Honing
    124
  - Honing Tools
    124
  - Honing Procedure
    124
  - Cleaning the Cylinder after Honing
    124
  - Crankshaft Truing
    125
- Special Tools
  117
  - Special Tools - Engine
    117
- Engine Mounting Systems
  126
- Recoil Assembly
  131
  - Rope Removal and Installation
    131
- Engine Component Assemblies
  132
- Cooling System
  151
  - Thermostat Replacement
    151
  - Thermostat Orientation
    151
  - 800 Thermostats
    151
  - 2010 600 Rush Cooling System
    152
  - 2012-2013 600 Rush/Switchback Cooling System
    155
  - Switchback Assault/Base Rmk Cooling System
    157
  - Pro Rmk/Rmk Assault Cooling System
    158
  - 600 INDY Cooling System
    159
  - Front Heat Exchanger Service
    160
- Exhaust Systems
  161
Chapter 4 Cleanfire Fuel Injection

165
- Service Warnings and Precautions
  167
- Engine Protection Features
  168
  - Engine Temperature Rpm Limit
    168
  - Engine Overheating Troubleshooting
    168
  - Detonation Protection (Det)/Rpm Limit
    169
  - Det Troubleshooting
    169
- Cleanfire Fuel Injection
  169
  - System Overview
    170
  - Fuel Select Feature
    171
  - Resistor Fuel Selector Plugs
    171
  - Dual Resistor Fuel Selector Plug
    171
  - Instrument Cluster Fuel Selector
    172
  - Diagnostic Trouble Codes (Dtcs)
    173
  - Diagnostic Trouble Code (Dtc) Troubleshooting
    175
  - Analog/Digital IC Error Code Display
    176
  - Digital IC Error Code Display
    176
  - Ecu 34 Pin Connector (Chassis)
    177
  - Ecu 26 Pin Connector (Engine)
    178
  - Exhaust Temperature Sensor
    179
  - Temperature / Air Pressure Sensor (Tmap)
    179
  - Crankshaft Position Sensors (Cps)
    179
  - Crankshaft Position Sensor Air Gaps
    179
  - Exhaust Valve Solenoid
    180
  - Ignition Coils
    180
  - Engine Coolant Temperature Sensor
    181
  - Knock (Det) Sensor
    181
  - Throttle Body Removal
    181
- DC-Cfi-4 Fuel Injectors/Fuel Rail
  182
  - Fuel Injectors
    182
  - Fuel Rail Bleeding / Pressure Testing
    182
  - Disconnect Fittings
    183
  - Fuel Rail/Injector Removal/Installation
    183
  - Fuel System Assembly
    186
- DC-Cfi-2 Fuel Injectors/Fuel Rail
  187
  - Fuel Injectors/Assembly
    187
  - Fuel Rail Bleeding / Pressure Testing
    188
  - Disconnect Fittings
    189
  - Quick Disconnect Fittings
    189
  - Fuel Rail Microdampers
    190
  - Fuel Rail/Injector Removal and Installation
    191
- Fuel Tank/Pump Service
  192
- Digital Wrench® Diagnostic Software
  198
  - Digital Wrench® Diagnostic Software Overview
    198
  - Special Tools
    198
  - Diagnostic Software Version
    198
  - Ecu Replacement
    198
  - Guided Diagnostics Available
    198
  - Digital Wrench® Communication Errors
    199
  - Digital Wrench® - Diagnostic / Power Connectors
    199
  - Digital Wrench® Serial Number Location
    200
  - Digital Wrench® Version and Update ID
    200
  - Digital Wrench® Updates
    200
  - Digital Wrench® Feature Map
    202
  - Updating Digital Wrench
    203
  - Version Identification
    204
  - Special Tests Menu
    204
  - Vehicle History Information
    204
  - Service Report
    204
  - Ecu Replacement
    205
  - Engine Controller Reprogramming (Reflash)
    205
  - Digital Wrench® Data Grid Screenshots
    208
- Throttle Position Sensor
  209
  - Throttle Position Sensor (Tps) Overview
    209
  - Tps Tests
    210
  - Tps Set Procedure Menu
    211
  - Throttle Position Sensor (Tps) Wire Harness Routing
    215
- Variable Exhaust System (Ves)
  215
  - Overview
    215
- Electronic Reverse (Perc)
  216
  - Overview
    216
  - Operation
    216
  - Forward Operation
    216
  - Altitude Setting
    217
  - Important Notes
    217
- Troubleshooting
  218
  - Engine will Not Start
    218
  - Engine Starts - Won't Idle/Stalls
    218
  - Poor Performance
    218
  - DC-Cfi Troubleshooting Flowchart
    219
  - Detonation Limit Troubleshooting Flowchart
    220
Chapter 5 Final Drive/Brake System

221
- Track Stud Specifications
  222
- Drive Gears/Chains
  223
  - Drive Gears
    223
  - Drive Chains
    223
- Gear Ratio Speed Chart
  224
  - 7.53 CD Chaincase Speed Chart
    224
- Chaincase
  225
  - Specifications/Torque Guide
    225
  - Chaincase Cover Torque Pattern
    225
  - Brake Caliper Types
    225
  - Full Assembly View
    226
  - Chaincase Disassembly
    227
  - Chaincase Assembly
    228
  - Mounting Assembly View
    230
  - Non-Bonded Chaincase Removal/Installation
    230
  - Bonded Chaincase Removal/Installation
    231
- Quickdrive™ Low Inertia Drive System
  232
- Driveshaft/Jackshaft
  238
  - Specifications/Torque Guide
    238
  - Assembly View
    238
  - Jackshaft Removal
    239
  - Jackshaft Installation
    239
  - Driveshaft Removal
    239
  - Driveshaft Installation
    239
- Brake System
  240
  - General Guidelines
    240
  - Overview
    241
  - Compensating Port
    241
  - Brake Fluid Replacement & Bleeding
    242
  - Combined Master Cylinder/Lever Service
    243
  - Cyclone Master Cylinder/Lever Service
    243
  - Brake Line Replacement
    244
  - Brake Hose Routing
    245
  - Combined MC Brake Light Switch Replacement
    245
  - Phantom Brake Caliper Removal
    246
  - Phantom Brake Caliper Installation
    246
  - Phantom Brake Caliper Piston and Seal Replacement
    246
  - Phantom Brake Pad Replacement
    247
  - Phantom Lite Brake Caliper Bracket/Seal/Piston Service
    248
  - Phantom Lite Brake Pad Replacement
    250
  - Brake Disc Replacement
    251
Chapter 6 Pvt System

253
- Pvt System
  254
- Special Tools
  256
- Drive Clutch Springs
  257
- Drive Clutch Weights
  258
- Spring Free Length
  258
- Perc Team Lwt Driven Helixes (24 Fin)
  259
- Team Ramp Angles
  259
- Team Driven Springs
  260
- Polaris P2 Driven Non-Tabbed Springs
  261
- Polaris P2 Tabbed Driven Springs
  261
- P2 Helix Angles
  262
- Polaris P2 Driven Helixes
  262
- Belt Inspection
  263
- Drive Belts
  263
- Belt Wear / Burn Diagnostics
  264
- Adjusting Belt Deflection - Team Driven Clutch
  265
- Drive Belt Installation - Team Driven
  265
- Drive Belt Removal - Team Driven
  265
- Adjusting Belt Deflection - Spa P2
  266
- Drive Belt Installation - Spa P2
  266
- Drive Belt Removal - Spa P2
  266
- Pvt System Adjustments
  267
- Drive Clutch
  269
  - Identification
    269
  - Drive Clutch Removal
    269
  - Drive Clutch Disassembly
    270
  - Roller Removal
    271
  - Roller Installation
    271
  - Spider Button Installation
    271
  - Bushing/Insert Replacement
    272
  - Moveable Sheave Bushing/Insert Removal and Installation
    272
  - Cover Bushing
    272
  - Clutch Assembly
    273
  - Belt-To-Sheave Clearance Adjustment
    273
  - Spider Indexing
    274
  - Drive Clutch Installation
    275
- Driven Clutch
  275
  - Driven Clutch Removal
    275
  - Driven Clutch Installation
    275
  - Team Lwt Components
    276
  - Polaris Spa-P2 Driven Clutch Components
    277
- Pvt System Troubleshooting
  278
  - Drive Belt
    278
  - Drive Clutch
    278
  - Driven Clutch
    278
Chapter 7 Shocks

279
- Special Tools
  280
- Valve Shims
  281
  - Fox™ Shock Valve Part Numbers
    281
  - Walker Evans™ Shock 3/8" Valve Part Numbers
    282
  - Valve Shim Arrangement
    283
  - Piston Orientation
    283
- Specifications
  284
  - 2011 Pro-Ride Model Shock Specifications
    287
  - 2012 Pro-Ride Model Shock Specifications
    290
- Shock Maintenance
  296
  - Walker Evans™ Coil-Over Piggyback Shock
    296
  - Fox™ Ifp Monotube Shock Disassembly
    300
  - Fox™ Ifp Monotube Shock Assembly
    301
  - Walker Evans™ Ifp Monotube Shock
    304
  - Fox™ Ps-5 Assembly View
    306
  - Fox™ Ps-5 Disassembly
    307
  - Fox™ Ps-5 Assembly
    310
  - Fox™ Zero Pro Assembly View
    313
  - Fox™ Zero Pro Shock Disassembly
    314
  - Fox™ Zero Pro Shock Assembly
    317
Chapter 8 Steering and Suspensions

321
- Inspection
  323
- Overview / Specifications
  323
- Rod End Engagement
  323
- Rod End Installation
  323
- Special Tools
  325
- Suspension Mounting Fastener Torque
  325
- Initial Shock Settings
  326
- Independent Front Suspension (Ifs) Shock Settings
  328
- Rebound Adjustment
  329
- Walker Evans™ Spring Retainers
  329
- Front Track Shock (Fts) Factory Settings
  330
- Rear Track Shock (Rts) Factory Settings
  331
- Limiter Straps - Indy / Rush / Rmk Models
  332
- Limiter Straps - Switchback 136 Models
  332
- Limiter Straps - Switchback 144 Models
  332
- Torsion Springs/Sag Setting
  333
- Scissor Stop Adjustment - Indy Models
  334
- Front Suspension Assembly Illustrations
  335
- Front Suspension Settings
  350
  - Overview
    350
  - Alignment Bar Specifications
    350
  - Maximum Setup Width
    350
  - Handlebar Centering
    351
  - Camber
    351
  - Camber Adjustment
    351
  - Toe Adjustment
    352
- Front Suspension Disassembly / Assembly
  353
  - Spindle Removal
    353
  - Spindle Assembly
    353
  - Upper/Lower Control Arm Removal
    354
  - Upper/Lower Control Arm Installation
    354
  - Spherical Bearing Replacement
    355
- Rear Suspension Assembly Illustrations
  356
- Pro-Ride Progressive Suspension Operation
  390
  - Operation
    390
  - Adjustment Procedures
    390
  - Rear Track Shock Thrust Bearing
    394
- Progressive Rear Suspension Removal and Installation
  395
  - Removal
    395
  - Rear Crank Service
    396
  - Rear Track Shock Service
    397
- Rmk Coil-Over Rear Suspension
  398
- Rail Sliders
  401
  - Wear Limit
    401
  - Removal/Installation
    401
  - Break-In
    401
  - Indy 121 Optional Bogie Wheels
    401
Chapter 9 Chassis

403
- General Cautions and Notes
  404
- Lord 406 Acrylic Adhesive Information
  404
- Safety Information
  404
- Specifications
  405
  - Fastener Torque Specifications
    405
- Chassis Assemblies
  406
- Bonded Component Service
  427
  - Overview
    427
  - Bonded Component Removal
    427
  - Bonded Component Surface Preparation
    427
  - Adhesive Applicator Kits
    428
  - Adhesive Application
    428
  - Adhesive Application Patterns
    429
  - Bulkhead Floor Plate Removal
    431
  - Bulkhead Floor Plate Installation
    431
  - Front Tunnel Bulkhead Cooler Removal
    431
  - Front Tunnel Bulkhead Cooler Installation
    432
  - Left Bulkhead Clip Removal
    433
  - Left Bulkhead Clip Installation
    435
  - Right Bulkhead Clip Removal
    436
  - Right Bulkhead Clip Installation
    439
  - Left Support Brace Removal
    441
  - Left Support Brace Installation
    442
  - Right Support Brace Removal
    442
  - Right Support Brace Installation
    444
Battery and Electrical Systems Chapter 10 Battery and Electrical

445
- Chapter 10
  447
- Charging/Lighting System
  447
- Engine Models
  447
- Ignition Timing
  447
- Spark Plugs
  447
- Specifications
  447
- Digital Instrument Cluster
  448
  - Overview
    448
  - Rider Information Display
    449
  - Instrument Cluster Pinouts
    449
  - Engine Rpm/Vehicle Speed Display
    449
  - Performance Information Area
    450
  - Vehicle Information Area
    450
  - Changing Units
    450
  - Diagnostic Display
    450
  - Playback Mode
    450
  - Fuel Select Mode
    451
- Analog/Digital Instrument Cluster
  452
  - Overview
    452
  - Rider Information Display
    453
  - Changing Units
    454
  - Fuel Selector
    454
  - Analog/Digital IC Error Code Display
    454
- Security System
  455
- Maintenance-Free Battery
  464
  - Specifications
    464
  - Battery Removal/Installation
    464
  - Battery Preparation
    464
  - Charging Procedure
    465
  - Battery Testing
    465
  - Ocv - Open Circuit Voltage Test
    465
  - Load Test
    465
  - Battery Conductance Analyzer
    466
  - Battery off Season Storage
    466
- Electric Start
  467
  - System Schematic
    467
  - Starter Motor/Flex Drive Assembly
    468
  - Starter Motor/Flex Drive Service
    468
  - Battery Box Assembly
    469
- Ignition Timing
  470
  - Timing Procedure
    470
  - Ignition Timing Chart
    471
- DC-Cfi Electrical Systems
  472
  - DC-Cfi Stator Assembly
    472
  - DC Regulator/Rectifier
    473
  - DC-Cfi Chassis Power Capacitor
    473
  - Ignition Coil Packs
    474
  - Exhaust Valve Solenoid
    474
  - Oil Level Sender
    475
  - Lh Control Assembly
    475
  - Auxiliary Stop Switch
    475
  - Throttle Release Switch
    476
  - Brake Switch
    476
  - Perc Switch
    476
  - DC-Cfi Regulated (Red) Power Circuits
    477
  - DC-Cfi Chassis (Red/White) Power Circuits
    478
  - DC-Cfi Ac Power (Lighting) Circuits
    479
  - DC-Cfi Throttle/Ignition Disable System
    480
- Diagnostic Plugs
  481
  - Power Test Plugs
    481
  - DC Pwr Plug
    481
  - Ecm Pwr Plug
    481
  - Fuel Pump Prime Plug
    481
  - Ac Pwr Plug
    481
- Hand/Thumb Warmers
  482
  - Thumb Warmer Diagnostics
    482
  - Thumb Warmer Resistance Checks
    482
  - Hand Warmer Diagnostics
    483
  - Hand Warmer Resistance Checks
    483
  - Full Length Hand Warmers
    484
  - Full Length Hand Warmer Resistance Checks
    484

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