Polaris Pro-Ride service manual 2010-2013

General Information

General Information CHAPTER 1 General Information 1 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 1.1

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2010 600 RUSH

General Information MODEL SPECIFICATIONS Clutch Settings 2010 600 RUSH Model Numbers: S10BF6KSA / S10BF6KSL / S10BF6KEA Engine Clutch Settings (Electric Start Models) Fuel Delivery NOTE: OPTIONAL - USE 2 GRAM LIGHTER CLUTCH WEIGHTS WHEN OPERATING IN PROLONGED WARM TEMPERATURES (LATE FALL/SPRING SEASON) TO MAINTAIN PEAK OPERATING RPM.

Track 1.2 ALTITUDE meters (feet) DRIVE CLUTCH P2 DRIVEN CLUTCH Shift Weight Clutch Spring Clutch Spring Driven Helix Gearing 0-600 (0-2000) 10-64 BLACK 120 - 310 7043601 130 - 180 Tabbed 7043515 58/42 - .45 5137176 23:39 - 72 600-1200 (2000-4000) 10-62 22:39 - 72 1200-1800 (4000-6000) 10-60 22:40 - 72 1800-2400 (6000-8000) 10-58 2400-3000 (8000-10,000) 10-56 20:41 - 72 3000-3600 (10,000-12,000) 10A-L Drive Clutch Bolt Torque: 80 ft-lbs (108Nm) Re-torque after running engine.

Engine Type Liberty Liquid-Cooled / Case Reed Induction Model Number S4202-6044-OP6N Displacement / # Cylinders 599cc / 2 Bore (inches/mm) 3.04 / 77.25 Stroke (inches/mm) 2.52 / 64 Piston to Cylinder Clearance (inches/mm) .0033-.0054 / 0.085-0.137 Installed Ring Gap (inches / mm) .014-.020 / 0.356 - 0.508 Operating RPM ±200 8250 Idle RPM 1700 Engagement RPM ±200 3800 Exhaust Valve Spring Purple Thermostat Opening Temperature (° F/ ° C) 120 / 49 ALTITUDE meters (feet) DRIVE CLUTCH P2 DRIVEN CLUTCH Shift Weight Clutch Spring Clutch Spring Driven Helix Gearing 0-600 (0-2000) 10-64 BLK/GRN 120 - 340 7042083 130 - 180 Tabbed 7043515 58/42 - .45 5137176 23:39 - 72 600-1200 (2000-4000) 10-62 22:39 - 72 1200-1800 (4000-6000) 10-60 22:40 - 72 1800-2400 (6000-8000) 10-58 2400-3000 (8000-10,000) 10-56 20:41 - 72 3000-3600 (10,000-12,000) 10A-L Drive Clutch Bolt Torque:

80 ft-lbs (108Nm) Re-torque after running engine. Type - Number of Fuel Injectors DC-CFI - 4 Throttle Body Marking 1203978 Throttle Body Bore 46mm TPS Voltage @ Idle (5 VDC +/- .01 Input) 0.95 +/- 0.01 VDC Fuel Pressure - PSI (bar) 58-60 (4.0-4.1) Fuel Octane (R+M/2) 10% Ethanol 24 Resistor Premium/Non-Ethanol 160 Resistor Width - Inches (cm) 15 (38) Length - Inches (cm) 120 (304.8) Pitch Plies 2.86 2 Lug Height - Inches (cm) 1.25 (3.175) (Ripsaw) Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/40cm ahead of rear idler shaft 7/8- 1-1/8(2.2 - 2.9cm)

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2010 600 RUSH

General Information General Rear Suspension 1 Electrical Front Suspension NOTE: * = Rider weight in everyday clothing. ** = From full soft (CCW) position.

1.3 Width (in/cm) 48 / 121.9 Length (in/cm) 108 / 274 Height (in/cm) 46 / 117 Estimated Dry Weight (lb/kg) 459 / 208 Fuel (Gallons / Liters) 11 / 41.6 Oil (Quarts / Liters) 3.4 / 3.3 Cooling System Capacity(Qts/ L) 5.25 / 5.0 Brake Fluid DOT 4 Drive Belt Part Number Width (inches / cm) Side Angle Circumference (inches / cm) Center Distance (inches / cm) 3211122 1.460 / 3.7 26° 46.77 / 118.8 11.5 / 29.2 Chaincase Center Distance (inches) Top Gear (Stock) Bottom Gear (Stock) Chain (Stock) Gear Lube Capacity (oz / ml) Reverse System 7.53 23 39 72 Polaris Synthetic (80W) 9 / 266 PERC Suspension Type Pro-Ride Progressive Front Track Shock (FTS) Walker Evans w/Remote Reservoir 16 Click Compression Adjustable Factory Setting** = 2 FTS Spring Rate lbs/in (N/mm) 120 - 310 (21 - 54.25) FTS Spring Installed Length Inches (cm) Preload = .75 (1.9) 7.75 (19.7) Rear Track Shock (RTS) Walker Evans Needle w/Remote Reservoir 16 Click Compression Adjustable Factory Setting** = 4 Standard RTS Spring Rider Weight* 120 - 250lbs.

Rate lbs/in (N/mm) PN: 7043572-385 190 (33.25) LW RTS Spring Rider Weight* 90 - 150lbs. Rate lbs/in (N/mm) PN: 7041575-385 120 (21) HD RTS Spring Rider Weight* 240 - 335+lbs. Rate lbs/in. (N/mm) PN: 7043585-385 260 (45.5) RTS Spring Rider / Weight Setting Spring length set to rider weight using adjustment gauge. STD Gauge PN: 5253792 LW Gauge PN: 5253854 HD Gauge PN: 5253855 (STD gauge in tool kit. LW and HD gauges are accessories and should be ordered when ordering a LW or HD spring.) Rider weight adjustment can also be performed using tape measure and RTS Spring Guide Table located in the Steering/Suspension Chapter.

Rear Travel Inches (cm) 14 (35.6) Alternator Output Operating Voltage Watts @ 13.5 VDC (Total) 13.5 - 14.5 VDC 400 Ignition Timing 18° @1700 RPM Coolant Temp = 120° F (49° C) Spark Plug Gap in.(mm) .027 (.70) Spark Plug NGK BPR9ES Suspension Type PRO-RIDE Shocks Walker Evans Needle w/Remote Reservoir 16 Click Compression Adjustable Factory Setting** = 6 IFS Spring Rate lbs/in (N/mm) 80 (14) IFS Spring Installed Length - Inches (cm) Preload = 3.75 (9.5) 10.25 (26) Front Vertical Travel Inches (cm) 9 (22.9) Ski Center Distance Inches (cm) Setup Width 42.5 (108) 41.52 (105) Camber Inches (cm) 1.68  0.31 (4.3  .8) Toe Out Inches (mm) 0 -1/8 (0 - 3)

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2011 600 RUSH

General Information 2011 600 RUSH Clutch Settings Model Numbers: 600 RUSH S11BF6NSA / S11BF6NSL / S11BF6NSB / S11BF6NSM 600 RUSH LX S11BD6NSL / S11BD6NSM 600 RUSH PRO-R S11BP6NSA / S11BP6NSL / S11PB6NEL / S11BP6NSB S11BP6NSM / S11BE6NSM Engine Clutch Settings (Electric Start Models) Fuel Delivery NOTE: OPTIONAL - USE 2 GRAM LIGHTER CLUTCH WEIGHTS WHEN OPERATING IN PROLONGED WARM TEMPERATURES (LATE FALL/SPRING SEASON) TO MAINTAIN PEAK OPERATING RPM.

Track 1.4 ALTITUDE meters (feet) DRIVE CLUTCH P2 DRIVEN CLUTCH Shift Weight Clutch Spring Clutch Spring Driven Helix Gearing 0-600 (0-2000) 10-64 BLACK 120 - 310 7043681 130 - 180 Tabbed 7043515 58/42 - .45 5137176 23:39 - 72 600-1200 (2000-4000) 10-62 22:39 - 72 1200-1800 (4000-6000) 10-60 22:40 - 72 1800-2400 (6000-8000) 10-58 2400-3000 (8000-10,000) 10-56 20:41 - 72 3000-3600 (10,000-12,000) 10A-L Drive Clutch Bolt Torque: 80 ft-lbs (108Nm) Re-torque after running engine.

Engine Type Liberty Liquid-Cooled / Case Reed Induction Model Number S4215-6044-OO6N Displacement / # Cylinders 599cc / 2 Bore (inches/mm) 3.04 / 77.25 Stroke (inches/mm) 2.52 / 64 Piston to Cylinder Clearance (inches/mm) .0033-.0054 / 0.085-0.137 Installed Ring Gap (inches / mm) .017-.025 / 0.450-0.650 Operating RPM ±200 8250 Idle RPM ±200 1700 Engagement RPM ±200 3800 Exhaust Valve Spring Purple Thermostat Opening Temperature (° F/ ° C) 120 / 49 ALTITUDE meters (feet) DRIVE CLUTCH P2 DRIVEN CLUTCH Shift Weight Clutch Spring Clutch Spring Driven Helix Gearing 0-600 (0-2000) 10-64 BLK/GRN 120 - 340 7042083 130 - 180 Tabbed 7043515 58/42 - .45 5137176 23:39 - 72 600-1200 (2000-4000) 10-62 22:39 - 72 1200-1800 (4000-6000) 10-60 22:40 - 72 1800-2400 (6000-8000) 10-58 2400-3000 (8000-10,000) 10-56 20:41 - 72 3000-3600 (10,000-12,000) 10A-L Drive Clutch Bolt Torque:

80 ft-lbs (108Nm) Re-torque after running engine. Type - Number of Fuel Injectors DC-CFI - 4 Throttle Body Marking 1203978 Throttle Body Bore 46mm TPS Voltage @ Idle (5 VDC +/- .01 Input) 0.95 +/- 0.01 VDC Fuel Pressure - PSI (bar) 58-60 (4.0-4.1) Fuel Octane (R+M/2) 10% Ethanol 24 Resistor Premium/Non-Ethanol 160 Resistor Width - Inches (cm) 15 (38) Length - Inches (cm) 121 (307) Pitch Plies 2.52 2 Lug Height - Inches (cm) RUSH RUSH PRO-R 1.0 (2.54) (Hacksaw) 1.25 (3.175) (Ripsaw) Track tension sag in/cm with 10 lbs/4.54kg placed 16 in/40cm ahead of rear idler shaft 1/2- 1.0(1.3 - 2.54cm)

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