Polaris 2016 600 Rush PRO-S- Manuals

5 INTRODUCTION Important Notes for Owners and Drivers After reading this manual, store it in the snowmobile for convenient reference. It should remain with the snowmobile when the snowmobile is sold. Some of the illustrations and photos used in this manual are general representations. Your model may...

6 INTRODUCTION Preservation of the Environment POLARIS is committed to supporting an environmental education campaign. We encourage state and provincial governments across the snowbelt to adopt rigorous safety training programs that encourage protection of our environment, including wildlife and veg...

7 INTRODUCTION Vehicle Identification Numbers Record your snowmobile's identification numbers and key number in the spaces provided. NOTE: The Vehicle Identification Number (VIN) is stamped into the side of the tunnel and printed on the tunnel VIN label. Vehicle Model Number: _______________________...

9 SAFETY Operator Safety The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal inju...

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

12 SAFETY Operator Safety Riding Apparel Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label. ...

13 SAFETY Operator Safety Disabled Operators Safe operation of this rider-active vehicle requires good judgement and physical skills. Operators with cognitive or physical disabilities have an increased risk of loss of control, which could result in serious injury or death. Survival Preparation For y...

14 SAFETY Operator Safety Rider Capacity Some POLARIS snowmobiles are designed for a single rider only, while some are designed for up to two riders. A safety label on the vehicle indicates whether the vehicle is designed for a single rider or for two riders. Driving With a Passenger 1. Do not carry...

15 SAFETY Operator Safety Driving With a Passenger 12. A passenger should always be seated in the passenger seat with both feet on the running boards/footrests and both hands on the passenger hand holds at all times. The passenger should never hold on to the operator. Never secure a passenger to the...

16 SAFETY Operator Safety Excessive Speed WARNING! High speed driving, especially at night, could result in serious injury or death. Always reduce speed when driving at night or in inclement weather. Always observe all state and local laws governing snowmobile operation and speed limits. Always be a...

17 SAFETY Operator Safety Driver Awareness Slow down when traveling near poles, posts, or other obstacles. Be especially alert if you're snowmobiling after dark. Always be on the alert for wire fences. Single strands are especially dangerous, since there may be a great distance between posts. Guy wi...

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

19 SAFETY Operator Safety Ice and Snow Build-up WARNING! Ice and snow build-up may interfere with the steering of your snowmobile, resulting in serious injury or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow ...

20 SAFETY Operator Safety Driving Downhill When riding downhill, shift your weight to the rear of the snowmobile and reduce your speed to a minimum. Apply just enough throttle to keep the clutch engaged, allowing the engine's compression to help slow the snowmobile and keep it from rolling freely do...

21 SAFETY Operator Safety Drive Belt Do not operate the engine with the drive belt removed. Any servicing that requires operation without a belt must be performed by your dealer. NOTICE: Operation of the engine with the belt removed may result in injury or damage to the engine. Intake Silencer Do no...

22 SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently, and even the most docile conditions may become dangerous if operators drive improperly. If you're new to snowmobiling, acquaint yourself with the snowmobile and with what it will and won't do under various conditions...

23 SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding. WINDCHILL CHART (°F) WINDCHILL CHART (°C) Wind Speed in MPH Actual Thermometer Reading ( ° F) 40 35 30 25 20 15 10 5 0 -5 -10 -15 -20 -25 ...

24 SAFETY Safety Labels and Locations Warning labels have been placed on the snowmobile for your protection. Read and follow the instructions of the labels and other warnings on the snowmobile carefully. If any of the labels depicted in this manual differ from the labels on your snowmobile, always r...

27 SAFETY Safety Labels and Locations Clutch Warning/Belt Removal WARNING Do not operate engine with hood or side panels open. Do not attempt adjustment with engine running. Do not operate engine with the clutch guard removed. Never run engine with drive belt removed. Never service clutches yourself...

28 FEATURES 8 13 5 7 12 11 2 1 4 1. Nosepan 2. Skis 3. Front Bumper 4. Hood 5. Headlight 6. Windshield (if equipped) 7. Handlebar 8. Operator Seat 9. Taillight 10. Rear Bumper 11. Snow Flap12. Suspension13. Track14. Side Panel15. Side Panel Fasteners16. Tool Kit (Inside engine compartment) 17. L-Wre...

30 FEATURES Adjustable Headlight The headlight can be adjusted for vertical aim using the following procedure. 1. In a well-ventilated area, position the snowmobile on a level surface with the headlight approximately 25 feet (7.6 m) from a wall. 2. Place the rider or the approximate weight of the ri...

31 FEATURES 12-Volt DC Power Receptacle If equipped, the 12-volt DC power receptacle is located on the hood next to the instrument cluster. The 12-volt power receptacle is protected by a 2 amp mini blade fuse located in the protective bag above the clutch cover. Use of the 12-volt DC power receptacl...

32 FEATURES Lighting and Warmers Power Management The following components are always powered when the engine is running: • Low Beam Headlights• Taillights/Brake Lights• Passenger Hand Warmers (if equipped) The brake light is protected by a 2 amp mini fuse located in the protective bag above the clu...

33 FEATURES Battery Charge Relay Control Some models are equipped with a battery. The battery provides power for only two purposes: • Engaging the electric starter motor to start the engine• Powering the Polaris Interactive Digital Display (IDD) with the ignition key when the engine is off The engin...

34 FEATURES Saddlebags Some snowmobiles are equipped with saddlebags. LOCK & RIDE saddlebags can be added as an accessory on other models. Please see your POLARIS dealer for more information. Three (3) locking plungers secure each saddlebag to the rear cargo rack. To remove a saddlebag, open eac...

35 FEATURES Fuel Type Selection Whenever using ethanol, MTBE or other forms of oxygenated gasoline, the fuel type designation setting must be changed to “Eth” in the gauge. When using the recommended 91 non-ethanol gasoline, always select the “91-non” setting. Whenever in doubt of your fuel purchase...

36 FEATURES Detonation Elimination Technology (DET) When DET senses and takes action to reduce detonation, the driver may notice a drop in engine RPM and/or reduced performance. The ECU will illuminate the check engine LED and display “dET” on the LCD screen whenever the DET system is active. If the...

37 FEATURES Detonation Elimination Technology (DET) The most likely causes of severe detonation are outlined in the troubleshooting table below. DET Troubleshooting Cause of DET Activation Solution Poor quality fuel Replace with higher quality fuel Incorrect ethanol/non-ethanol fuel type setting Ver...

38 FEATURES Engine Overheat Indicators Over-Temperature Indicator (Standard Cluster) The over-temperature indicator on the standard instrument cluster will illuminate when the engine is overheating. Take action to cool the engine. See page 39. The indicator will flash when engine temperature reaches...

39 FEATURES Engine Overheat Indicators Engine-Cooling Actions If the engine is overheating, promptly take action to cool the engine. • Drive in loose snow.• View the coolant level. Do not open the pressure cap while the engine is hot . Add coolant if the level is low. • Stop the engine and allow it ...

41 FEATURES Standard Instrument Cluster Indicators Check Engine Indicator This indicator appears if an EFI-related fault occurs. Do not operate the snowmobile if this warning appears. Serious engine damage could result. See your dealer. See page 102 for diagnostic code definitions. Over-Temperature ...

42 FEATURES Standard Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. The center displays vehicle speed, engine speed, odometer, resettable trip meters (2), total engine hours of operation, fuel level, engine temperature and diagnostic di...

43 FEATURES Standard Instrument Cluster Rider Information Center 1. Information Display Area - This area displays either engine speed or vehicle speed (whichever is not displayed in the speed display), engine temperature and maximum vehicle speed. To change the dis-play, see page 44. 2. Speed Displa...

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

45 FEATURES Standard Instrument Cluster Rider Information Center Odometer/Engine Hour Display Area This area displays the odometer, Trip A meter, Trip B meter and engine hours meter. The odometer displays the total distance traveled by the vehicle since manufacture. Each trip meter records the dista...

46 FEATURES Standard Instrument Cluster Rider Information Center Standard/Metric Display The odometer and temperature displays can be viewed in either standard or metric units of measurement. Both displays change if units are changed. The new settings will remain until changed by the operator. Chang...

48 FEATURES Standard Instrument Cluster Rider Information Center Security System (Ignition Lock System) First Time Use of Your Security System Perform all tasks in the order shown if you wish to activate and use the optional security system. TASK 1: Activate the security system See your authorized P...

50 FEATURES Standard Instrument Cluster Rider Information Center Security System (Ignition Lock System) Locking the System With Your Personal Security Code 1. Start the engine and lock the parking brake. 2. Press and hold the MODE and SEL buttons for 3 seconds, then release. SECURE OFF should be dis...

51 FEATURES Standard Instrument Cluster Rider Information Center Security System (Ignition Lock System) Unlocking the System With Your Personal Security Code 1. When the engine is running, the display will alternate between SECURE ON and ENTER CODE. Wait until ENTER CODE displays, then press and rel...

52 FEATURES Standard Instrument Cluster Rider Information Center Security System (Ignition Lock System) Changing to a New Security Code Any time you wish to change your current security code to a new code, perform TASK 2 through TASK 4 of the First Time Use of Your Security System procedure beginnin...

53 FEATURES Standard Instrument Cluster Rider Information Center Diagnostic Display Mode The diagnostic display mode is for informational purposes only. Please see your POLARIS dealer for all major repairs. The diagnostic mode is accessible only when the check engine warning indicator is illuminated...

54 FEATURES Interactive Digital Display (IDD) The Interactive Digital Display (IDD) provides the rider with: • Speedometer• Tachometer• Odometer• 2 Trip Meters• Fuel Level Indicator• Coolant Temperature• Battery Voltage• Fuel Type Selection• Vehicle Security CAUTION! Use a microfiber hand towel to c...

55 THE PERFECT FIT Suspension Quick Set-Up Guide Introduction The front suspension and PRO-XC rear suspension on your AXYS snowmobile is incredibly easy to adjust. Just remember three simple steps: 1. Ride your snowmobile! 2. Adjust the rear track shock spring to tune vehicle balance (ski pressure a...

56 THE PERFECT FIT Suspension Quick Set-Up Guide Ride Experience Table Ride Experience Adjustment Too “LITE”•Ski pressure is too light•Skis push Increase rear track shock spring preloadORDecrease front track shock spring preload Too much “BITE”•Ski pressure is too heavy•Steering is heavy Decrease re...

57 THE PERFECT FIT Suspension Quick Set-Up Guide Shock Locations REAR TRACK SHOCK FRONT (IFS) SHOCKS FRONT TRACK SHOCK MORE LITE MORE BITE

58 THE PERFECT FIT Suspension Quick Set-Up Guide Front Suspension (IFS) Factory Spring Settings CAUTION! Never exceed the minimum/maximum spring preload settings. Always remove the vehicle weight from the spring prior to making adjustments. Front Suspension (IFS) Factory Clicker Settings Front Suspe...

59 THE PERFECT FIT Suspension Quick Set-Up Guide Front (IFS) Shock Adjustments SOFTER TALLER STIFFER LOWER M E A S U R E H E R E SWITCHBACK ADVENTURE RUSH LTD (Low Speed Adjustment) RUSH LTD (High Speed Adjustment) SOFTER STIFFER STIFFER SOFTER ALL PRO-S/PRO-X/SWITCHBACK ADVENTURE (INTL) MODELS STIF...

60 THE PERFECT FIT Suspension Quick Set-Up Guide Front Track Shock Factory Spring Settings CAUTION! Never exceed the minimum/maximum spring preload settings. Always remove the vehicle weight from the spring prior to making adjustments. Front Track Shock Factory Clicker Settings Spring Setting Model ...

61 THE PERFECT FIT Suspension Quick Set-Up Guide Front Track Shock Adjustments SOFTER MEASURE HERE STIFFER MORE LITE MORE BITE SWITCHBACK ADVENTURE STIFFER SOFTER ALL MODELS EXCEPT SWITCHBACK ADVENTURE

62 THE PERFECT FIT Suspension Quick Set-Up Guide Rear Track Shock Factory Spring Settings CAUTION! Never exceed the minimum/maximum spring preload settings. Always remove the vehicle weight from the spring prior to making adjustments. Rear Track Shock Factory Clicker Settings Rear Track Shock HI/LO ...

63 THE PERFECT FIT Suspension Quick Setup Guide Rear Track Shock Adjustments SOFTER ME AS UR E HE RE STIFFER MORE LITE MORE BITE RUSH LTD (Low Speed Adjustment) RUSH LTD (High Speed Adjustment) ALL PRO-S/PRO-X/SWITCHBACK ADVENTURE (INTL) MODELS SOFTER SOFTER STIFFER STIFFER STIFFER SOFTER SWITCHBACK...

64 THE PERFECT FIT Suspension Quick Setup Guide Rear Track Shock Air Pressure (SWITCHBACK ADVENTURE) The factory-installed air assist rear shock contains zero air pressure, which will provide an optimum ride when combined rider and cargo weight is less than 200 lbs. (90.7 kg). If rider and cargo wei...

65 THE PERFECT FIT Suspension Quick Setup Guide Rear Track Shock Air Pressure (SWITCHBACK ADVENTURE) 4. Continue pumping to the desired pressure setting. NOTICE: Do not exceed 50 PSI (345 kPa). 5. To decrease pressure, push the black bleed valve button. When held partially depressed, air will escape...

66 THE PERFECT FIT Suspension Quick Setup Guide Limiter Strap Adjustment The front torque arm limiter strap is set at position #1. POLARIS recommends leaving the limiter strap length at position #1 to maintain the optimum ride characteristics of the snowmobile. Riders who desire less ski pressure an...

67 THE PERFECT FIT Handlebar Adjustments Riser Angle Riser angle can be adjusted to suit rider preference. Factory settings are shown below. 1. Loosen the four bolts on the bottom of the adjuster block. If necessary, pry the blocks apart with a screwdriver. 2. Adjust the riser forward or rearward to...

68 THE PERFECT FIT Handlebar Adjustments Riser Height (RUSH LTD) 1. Release the riser clamp. 2. Adjust the handlebar upward or downward to the desired height. 3. Secure the riser clamp. Handlebar Riser Clamp Riser

69 THE PERFECT FIT Handlebar Adjustments Handlebar Angle Handlebar angle can be adjusted to suit rider preference. Factory settings are shown below. 1. Loosen the four bolts on the top riser block. 2. Adjust the handlebar upward or downward to the desired angle. Be sure the handlebar, brake lever an...

70 THE PERFECT FIT Handlebar Component Fastener Torques Component Torque Do not over-tighten IMPORTANT: Moving a handlebar component without first loosening its screws/set screws may cut grooves into the handlebar, making it difficult to secure the component. Do not move a handlebar component withou...

71 THE PERFECT FIT Left Hand Control Adjustment IMPORTANT: Moving the left hand control without loosening the four mounting screws will cause the housing locating pins to cut grooves into the handlebar. When this occurs, the left hand control may not clamp tightly to the handlebar. If the left hand ...

72 THE PERFECT FIT Handlebar Component Locations Refer to the following illustration and measurements to position handlebar components at factory-specified locations. Handlebar Component Alignment Measurements 1. .011 in. (3 mm) 2. 6.65 in. (169 mm) 3. 6.7 in. (170 mm) 4. 10 in. (254 mm) 5. .47 in. ...

73 THE PERFECT FIT Traction Products Studs NOTICE: Failure to heed the following recommendations will result in tunnel or track damage and a voided warranty. The track is not warranted by POLARIS if studs have been installed. Track warranties are also void if track damage or failure results from the...

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

77 PRE-RIDE INSPECTIONS Pre-Ride Suspension Inspection Loose nuts and bolts can reduce your snowmobile’s reliability and cause needless repairs and down time. Before beginning any snowmobile trip, a visual inspection will uncover potential problems. Check the following items on a weekly basis or bef...

78 PRE-RIDE INSPECTIONS Before Starting the Engine Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start the engine without checking all vehicle components to be sure of proper operation. WARNING! Operating the vehicle with worn, damaged, or ...

79 PRE-RIDE INSPECTIONS Before Starting the Engine Brakes Always check the following items for proper operation before starting the engine. Brake Lever Travel NOTICE: Do not pump the brake lever when performing this procedure. Squeeze the brake lever. It should move no closer to the handgrip than 1/...

80 PRE-RIDE INSPECTIONS Before Starting the Engine Parking Brake Lever Lock Use the parking brake lever lock only when you want the snowmobile to remain stationary; for example, when parked on an incline for a period of five minutes or less. 1. Brake Lever 2. Fluid Level Indicator 3. Master Cylinder...

81 PRE-RIDE INSPECTIONS Before Starting the Engine Steering System WARNING! Ice and snow build-up may interfere with the steering of your snowmobile, resulting in serious injury or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be...

82 PRE-RIDE INSPECTIONS Start the Engine and Check Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never engage the starter when the engine is running. Never start the engine without checking all vehicle components to be sure of proper operation. S...

83 OPERATION Ignition Switch The ignition switch has three positions. If equipped with electric start, turn the key to START to crank the engine. When the key is released, it automatically returns to the RUN position. Snowmobiles equipped with electric start and/or IDD are equipped with a battery. I...

84 OPERATION Starting the Engine NOTICE: Engaging the starter when the engine is running WILL result in serious engine damage, especially if the snowmobile is in reverse. Never engage the starter when the engine is running. 1. Turn the key to the RUN position. 2. Pull the auxiliary engine stop switc...

85 OPERATION Break-In Period Engine Break-In The recommended break-in period is the time required to use the first full tank of pre-mixed fuel. Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts. Do not operate at full throttle or high speeds for ...

86 OPERATION Break-In Period Engine Break-In Never mix brands of oil. Serious chemical reactions can cause injection system blockage, resulting in serious engine damage. Oils may also be incompatible and the result could be sludge formation, filter blockage, and reduced cold weather flow rates. All ...

87 OPERATION Track Warm-Up WARNING! A loose track or flying debris could cause serious injury or death. Stand clear of the front of the snowmobile and the moving track. Never hold the snowmobile up or stand behind it while warming up the track. Do not use excessive throttle during warm-up or when th...

89 OPERATION Fuel Recommendation For peak performance, POLARIS recommends the use of 91 octane fuel or higher. Although 87 octane fuel is usable, some engine performance will be lost and fuel economy will decrease. Do not use lower than 87 octane fuel. Do not use fuel containing more than 10% ethano...

90 OPERATION Oil Low Oil Level Always maintain the oil level between the “ADD” mark and the bottle neck. Do not fill the bottle neck. See page 85 for oil recommendations. 1. Immediately stop the engine if the low oil indicator light comes on. 2. Open the left side panel. See page 104. 3. View the oi...

91 OPERATION Auxiliary Engine Stop Switch Push the auxiliary engine stop switch down to ground out the ignition and stop the engine quickly. Pull the switch up to the RUN position to allow restarting. Throttle Release Switch The throttle release switch is designed to stop the engine if all pressure ...

92 OPERATION Throttle Lever WARNING! An improperly functioning throttle lever may cause erratic snowmobile behavior and loss of control, which could result in serious injury or death. If the throttle lever does not work properly, DO NOT start the engine. If the engine stops abruptly when the throttl...

93 OPERATION Throttle Lever Throttle Lever Freeplay Adjustment Adjust throttle lever freeplay using the in-line throttle cable adjuster. 1. Locate the in-line adjuster on the throttle cable. 2. Loosen the lock nut. 3. Rotate the adjuster clockwise to DECREASE freeplay. Rotate the adjuster counter-cl...

94 OPERATION POLARIS Electronic Reverse Control (PERC) Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Damage will occur to the chaincase if shifting is attempted when the engine is operating above idle speed. • Shift to or from revers...

95 OPERATION POLARIS Electronic Reverse (PERC) Engaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Make sure the area behind your vehicle is clear. 3. Push the yellow reverse button on the left-hand control for one second, then release. The engine will automatically reduce RPM an...

96 OPERATION Daily Storage At the end of each ride, park the snowmobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4 inches (10 cm) off the ground. Remove the key and cover the snowmobile. Towing For your safety, do not ...

97 MAINTENANCE Emission Control Information Any qualified repair shop or qualified person may maintain, replace, or repair the emission control devices or systems on your snowmobile. Emission Control Label Your snowmobile is equipped at the time of sale with an emission control information (ECI) lab...

98 MAINTENANCE POLARIS Recommended Maintenance Program To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as outlined in this manual. Record maintenance and service in the Maintenance Log beginning on page 183. The recommend...

99 MAINTENANCE Periodic Maintenance Interval Table The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. When inspection reveals the need for replacement parts, always use genuine POLARIS parts, available from your POLARIS d...

102 MAINTENANCE Diagnostic Display Code Definitions Open Load: There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed. Short-to-Ground: The wire is shorted to ground between the electronic control unit and the item listed in the ch...

104 MAINTENANCE Hood and Side Panels The hood and side panels protect the operator from moving parts. Never operate a snowmobile with the side panels open or removed. Always ensure that the hood and side panels are installed and securely latched before starting the engine. Side Panels (Opening/Remov...

105 MAINTENANCE Hood Removal and Installation 1. Remove the side panels. 2. Rotate the 1/4-turn fasteners at the upper corners of the hood. 3. Disconnect the wire harness leading to the console electronics. 4. Remove the hood assembly. 5. To reinstall the hood, slide the nose clips into the nosepan....

106 MAINTENANCE Tools The belt removal L-wrench tool and the spare belt, spark plug and spark plug tool container are located behind the left engine compartment panel. When properly engaged in the bracket, the L-wrench secures the fender to the console. To retrieve the L-wrench, rotate it counter-cl...

108 MAINTENANCE Rear Shock Body Lubricate rear shock body threads seasonally with a low-temperature synthetic grease. Driveshaft Bearing This model has sealed bearings that require no additional lubrication. Chaincase Oil Check and change the chaincase oil at the intervals outlined in the Periodic M...

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

111 MAINTENANCE Chaincase Oil Oil Change (Cover Drain Method) 10. Using a funnel, slowly add the recommended oil until the fluid begins to overflow. Maximum fluid capacity is 10.5 oz. (310 ml). 11. Clean the area with a clean, dry shop towel. 12. Reinstall the fill plug. Torque: 6-10 ft-lbs (8-13 Nm...

112 MAINTENANCE Intake Filters The intake foam filters limit snow ingestion into the intake system. When operating in loose powder snow, check the foam filters periodically to remove any accumulation of snow. Foam Filters

113 MAINTENANCE Spark Plugs Spark Plug Recommendations A new engine can cause temporary spark plug fouling due to the preservative added during the assembly process. Avoid prolonged idle speeds, which cause plug fouling and carbonization. Change the spark plugs at the intervals outlined in the Perio...

114 MAINTENANCE Spark Plugs Spark Plug Inspection Spark plug condition is indicative of engine operation. The spark plug firing end condition should be read after the engine has been warmed up and the vehicle has been driven at higher speeds. Immediately check the spark plug for correct color. CAUTI...

115 MAINTENANCE Cooling System Coolant The coolant supplied in the system at the factory is a 50/50 mixture of ethylene-glycol and distilled water, which will provide adequate freeze protection under most conditions. If the vehicle will be stored or operated at extremely low temperatures, greater pr...

116 MAINTENANCE Cooling System Flushing the Cooling System To ensure that the coolant maintains its ability to protect the engine, drain the system completely every five (5) years and add a fresh mixture of antifreeze and distilled water. This service must be performed when the engine is cold. Ask y...

117 MAINTENANCE Cooling System Bleeding the Cooling System 6. Fill the coolant bottle to the COLD FILL mark. 7. Install the coolant bottle cap to the first lock. Do not tighten to the fully seated position. 8. Lock the parking brake. 9. Start the engine and allow it to run at a fast idle for several...

118 MAINTENANCE Exhaust System Check the exhaust system for wear or damage at approximately 2,000 miles (3200 km). Always allow the engine and exhaust system to cool completely before inspecting. CAUTION! Hot exhaust system parts can cause burns. Allow adequate time for the exhaust system to cool. N...

119 MAINTENANCE Drive Chain Tension Check drive chain tension at the intervals outlined in the Periodic Maintenance Table beginning on page 98. Check again before each long trip. CAUTION! Hot exhaust system parts can cause burns. Allow adequate time for the exhaust system to cool. Never perform this...

120 MAINTENANCE Brakes Hydraulic Brake Inspection Inspect brake lever travel before each use of the snowmobile. See page 79. Brake pads must be replaced when the brake pad material becomes thinner than the backing plate (approximately 1/16 inch or 1.5 mm). A kit is available for replacing brake pads...

121 MAINTENANCE Brakes Brake Fluid Replace brake fluid at least every two years with POLARIS DOT 4 high temperature brake fluid. See page 149 for the part numbers of POLARIS products. WARNING! After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bott...

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

123 MAINTENANCE Lights The headlight and taillight assemblies feature LED elements and are not serviceable. If an LED fails to illuminate in either the headlight or taillight, the entire assembly must be replaced. Please see your POLARIS dealer. Headlight Taillight

124 MAINTENANCE Fuse Replacement If the engine stops or will not start, or if an electrical component fails to operate, a fuse may need replacement. Locate and correct any damage or short circuits that may have caused the blown fuse, then replace the fuse. NOTICE: Always replace a blown fuse with a ...

125 MAINTENANCE Clutch System Periodically inspect clutch sheaves for damage, wear or belt residue. To maintain optimum performance, clean with non-oil based cleaners such as isopropyl alcohol. WARNING! If you become aware of higher than normal clutch engagement or an unusual vibration or shift patt...

126 MAINTENANCE Clutch System Drive Belt Condition Periodically check the condition and tension of the drive belt. Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions exist. See Drive Belt Troubleshooti...

127 MAINTENANCE Clutch System Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge (1) on the belt and apply downward pressure while measuring at point 2. This measurement should be 1 1/4 inches (3.2 cm). Drive Belt Deflec...

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

129 MAINTENANCE Clutch System Drive Belt Installation 1. Verify the driven clutch sheaves are open. If they are not, install the L-wrench and open the sheaves. NOTE: When installing the belt, verify POLARIS or the part number can be read from the outside of the snowmobile. 2. Drop the drive belt ove...

130 MAINTENANCE Track Maintenance Track Inspection WARNING! Broken track rods can cause a rotating track to come off the snowmobile, which could cause serious injury or death. Never operate with a damaged track. Never rotate a damaged track under power. 1. Using a hoist, safely lift and support the ...

131 MAINTENANCE Track Maintenance WARNING! Moving parts can cut and crush body parts. When performing the checks and adjustments recommended on the following pages, stay clear of all moving parts. Never perform track measurement or adjustments with the engine running. Track Tension Track adjustment ...

132 MAINTENANCE Track Maintenance Track Tension 5. Check for specified slack between the wear surface of the track clip and the plastic slider. Refer to the Track Tension Data Chart on page 131. If the track needs adjustment: 6. Loosen the rear idler shaft bolt. 7. Loosen the locknuts. 8. Tighten or...

133 MAINTENANCE Track Maintenance Track Alignment Periodically check that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. 1. Safely support the rear of the snowmobile with the track off the ground. 2. Start the engine a...

134 MAINTENANCE Steering System Front Suspension Inspection WARNING! Improper fastener torque or front suspension component damage may cause loss of steering control, resulting in serious injury or death. See your POLARIS dealer. Each week, or before a long ride, check the following items. If compon...

135 MAINTENANCE Steering System Ski Alignment WARNING! Improper ski alignment or adjustment may cause loss of steering control, resulting in serious injury or death. Do not attempt to change the ski alignment or toe adjustment. See your POLARIS dealer. If the steering feels heavy, or if the snowmobi...

136 MAINTENANCE Steering System Ski Skags WARNING! Worn skis and/or skags will adversely affect handling. Loss of vehicle control may result, causing serious injury or death. See your dealer's studding chart for recommended skags. If you install longer or more aggressive carbide skags than the origi...

137 MAINTENANCE Front Suspension Control Arms Control Arm Pivot Adjustment The upper and lower control arms feature slotted pivots to allow for adjustment to compensate for bushing wear. NOTE: Upper control arm shown. Procedure is the same for lower control arm adjustment. 1. Loosen the four lock nu...

138 MAINTENANCE Rear Suspension Rear Suspension Inspection WARNING! Improper fastener torque or rear suspension component damage may cause loss of vehicle control, resulting in serious injury or death. See your POLARIS dealer. Each week, or before a long ride, check the following items. If component...

139 MAINTENANCE Rear Suspension Rail Slide Wear Measure slide thickness at several points along the rail. Have your dealer replace the slide when it's worn down to the top of the wear limit indicator groove. Do not operate the snowmobile if slide thickness measures less than 7/16 inch (1.1 cm). 7/16...

140 MAINTENANCE Battery (if equipped) WARNING! Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative...

141 MAINTENANCE Battery (if equipped) Battery Removal 7. Remove the fasteners (6) (7) securing the battery bracket to the chassis. 8. Pull the fender away from the battery compartment and remove the battery/battery bracket assembly. 9. Remove the battery hold- down strap. 10. Remove the screw (4) se...

142 MAINTENANCE Battery (if equipped) Battery Installation Using a new battery that has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 144 before installing the battery. 1. Place the...

143 MAINTENANCE Battery (if equipped) Battery Installation 8. Connect and tighten the black (negative) cable last. CAUTION! Verify the battery cables and wiring harness do not come into contact with the brake disc. Move the wiring harness/cables behind the chassis tube and away from the brake disc. ...

144 MAINTENANCE Battery (if equipped) Battery Storage Whenever the vehicle is not used for a period of three months or more, remove the battery from the vehicle, ensure that it's fully charged, and store it out of the sun in a cool, dry place. Check battery voltage each month during storage and rech...

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

146 MAINTENANCE Fall Tune-Up For maximum performance, arrange for a fall service tune-up with your POLARIS dealer. His experienced and trained service technician will keep your snowmobile in peak operating condition. Matte Clear Coat Cleaning (if equipped) Matte finish products are prone to trapping...

147 MAINTENANCE Cleaning and Preservation Proper storage starts with cleaning, washing, and waxing the hood, side panels, chassis, and plastic parts. Wipe down remaining surfaces with a damp cloth. Clean and touch up with paint any rusted or previously painted surfaces. Be sure that corrosive salt a...

148 MAINTENANCE Extended Storage Clutch and Drive System Remove the drive belt and store in a cool dry location. Do not lubricate clutch components, except the driven clutch shaft bushing as outlined in the Master Repair Manual. See your dealer. Engine Protection Proper preparation of the engine and...

149 POLARIS PRODUCTS Part No. Description Engine Lubricants 2870791 Fogging Oil (12 oz. Aerosol) 2878243 VES RACE 2-Cycle Engine Oil (qt./.95 l) 2878191 VES RACE 2-Cycle Engine Oil (gal./3.8 l) 2877882 VES 2-Cycle Oil (qt./.95 l) 2877953 VES 2-Cycle Engine Oil (2 qt./1.9 l) 2877883 VES 2-Cycle Engin...

150 SPECIFICATIONS 600 RUSH PRO-S Capacities and Dimensions Body Style AXYS Rider Capacity 1 Coolant Capacity 4 qts. (3.8 l) Chaincase Oil Capacity Fill to Spill / 8 - 10 oz. (237 - 296 ml)Dependent on sprocket / chain size Fuel Tank Capacity 12 gal. (45.4 l) Height 46 inches (117 cm) Length 114 inc...

151 SPECIFICATIONS 600 RUSH PRO-S 600 RUSH PRO-S Traction / Control Clutching Chart ALTITUDE Meters (Feet) Drive Clutch Shift Weight Drive Clutch Spring Driven Clutch Spring Driven Helix Chaincase Gearing/ Pitch *Shaded cells indicate factory settings. 0-600 (0-2000) 10-64 1321585 140/330 7043829 Bl...

158 SPECIFICATIONS 600 SWITCHBACK ADVENTURE Capacities and Dimensions Body Style AXYS Rider Capacity 1 Coolant Capacity 4 qts. (3.8 l) Chaincase Oil Capacity Fill to Spill / 8 - 10 oz. (237 - 296 ml)Dependent on sprocket / chain size Fuel Tank Capacity 12 gal. (45.4 l) Height 49 inches (124.5 cm) Le...

166 SPECIFICATIONS 800 SWITCHBACK ADVENTURE Capacities and Dimensions Body Style AXYS Rider Capacity 1 Coolant Capacity 4 qts. (3.8 l) Chaincase Oil Capacity Fill to Spill / 8 - 10 oz. (237 - 296 ml)Dependent on sprocket / chain size Fuel Tank Capacity 12 gal. (45.4 l) Height 46 inches (117 cm) Leng...

170 TROUBLESHOOTING Engine Troubleshooting Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Probable Cause Solution Erratic engine operating RPM during acceleration or load variations Drive clutch binding • SEE YOUR DEALER. Driv...

173 TROUBLESHOOTING Suspension Troubleshooting Problem Solution Rear suspension bottoms too easily • Adjust rear track shock clicker stiffer (see pages 62-63).• Verify rear spring is not broken/dislodged.• Rebuild rear track shock (see your dealer). Rides too stiff in rear • Check for binding suspen...

174 TROUBLESHOOTING Drive Belt Troubleshooting Belt Wear/Burn Diagnosis Causes Solutions Driving at low RPM • Drive at higher RPMs. Gear the machine down. Check belt deflection. Parking brake engaged • Verify parking brake is not engaged. Insufficient warm-up • Warm the engine at least five minutes....

175 WARRANTY Service and Warranty Information Obtaining Service and Warranty Assistance Read and understand the service data and the POLARIS warranty information contained in this manual. Contact your POLARIS dealer for replacement parts, service or warranty. Your dealer receives frequent updates on...

176 WARRANTY Limited Warranty POLARIS Industries Inc., 2100 Highway 55, Medina, MN 55340 (POLARIS) gives a 12 MONTH LIMITED WARRANTY on all components of your POLARIS vehicle against defects in material or workmanship. This warranty covers parts and labor charges for repair or replacement of defecti...

177 WARRANTY Warranty Coverage and Exclusions Limitations of Warranties and Remedies This POLARIS Limited Warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God,...

179 WARRANTY How to Obtain Warranty Service If your vehicle requires warranty service, you must take it to a POLARIS Servicing Dealer. When requesting warranty service you must present your copy of the Warranty Registration Form to the dealer. (THE COST OF TRANSPORTATION TO AND FROM THE DEALER IS YO...

180 WARRANTY Exported Products EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WARRANTY OR SERVICE BULLETIN COVERAGE ON THIS PRODUCT IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER’S AUTHORIZED LOCATION. This policy does not apply to products that have received authorization for expor...

183 MAINTENANCE LOG Present this section of your manual to your dealer each time your snowmobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 150 mi. (240 km)...

186 INDEX 0-9 12-Volt DC Power Receptacle. . . . . 3112-Volt RCA Power Sources . . . . . . 3112-Volt Receptacle Fuse . . . . . . . . 124 A Adjustable Headlights . . . . . . . . . . . 30Avalanches. . . . . . . . . . . . . . . . . . . . 18 B Battery Charge Relay Control . . . . . . . . . 33Charging . ...