Polaris 600 Rush-Pro-R - Manual

6 INTRODUCTION Preservation of the Environment POLARIS is committed to supporting an environmental education cam-paign. We encourage state and provincial governments across the snow-belt to adopt rigorous safety training programs that encourage protection of our environment, including wildlife and v...

7 INTRODUCTION Vehicle Identification Numbers Record your snowmobile's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a POLARIS key blank with one of your existing keys, so if both keys are lo...

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

9 SAFETY Operator Safety Follow the recommended maintenance program beginning on page 81 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals. Driving a snowmobile requires your full attention. DO NOT drink alco...

10 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,...

11 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 estab-lished safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label....

12 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...

13 SAFETY Operator Safety Rider Capacity This snowmobile is designed for a single rider only. Never carry a pas-senger on this snowmobile. Excessive Speed WARNING! High speed driving, especially at night, could result in serious injury or death. Always reduce speed when driving at night or in inclem...

14 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...

15 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...

16 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 ...

17 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...

18 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...

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

20 SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when tem-peratures become dangerous for riding. WINDCHILL CHART (°F) 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...

21 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...

22 SAFETY Safety Labels and Locations Track Warning WARNING Stay clear of track. Do not sit on seat back. Entangle-ment with the track or a fall from seat back may result in severe injury or death. No Passenger Warning/Fuel Recommendation Label WARNING This vehicle is designed for operator only. NO ...

23 SAFETY Safety Labels and Locations Operation Warning WARNING • To avoid serious injury or death, read and understand all warn-ings and the Owner's Manual before operation. If manual is missing, contact a POLARIS dealer for a replacement. • This vehicle is capable of high speeds. Buried objects or...

24 FEATURES 8 13 5 6 7 12 11 2 1 3 4 10 9 1. Nosepan 2. Skis 3. Front Bumper 4. Hood 5. Headlight 6. Windshield (accessory) 7. Handlebar 8. Operator Seat 9. Taillight 10. Rear Bumper11. Snow Flap12. Suspension13. Track14. Side Panel15. Side Panel Fasteners16. Tool Kit/Storage Bag 15 14 16

26 FEATURES Adjustable Headlights Move the headlight adjuster to the left to adjust the headlight beam upward. Move the adjuster to the right to adjust the beam down-ward. Up Down

27 FEATURES Fuel Type Selection Whenever using ethanol, MTBE or other forms of oxygenated gaso-lines, 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 purcha...

28 FEATURES Detonation Elimination Technology (DET) The DET system prevents damage to the engine from detonation by going into an engine protection mode whenever the DET system is active. When excessive detonation is detected, the check engine light will illuminate and you may notice decreased engin...

29 FEATURES Detonation Elimination Technology (DET) The most likely causes of severe detonation are outlined in the trouble-shooting table below. DET Troubleshooting Security System (Ignition Lock System) Your snowmobile has an optional security function that can be activated by an authorized POLARI...

30 FEATURES Instrument Cluster The instrument cluster contains indicator lights and the rider infor-mation center. The information cen-ter can be controlled by either the MODE and SELECT buttons on the instrument cluster or by the MODE/SET switch on the left handlebar. NOTICE: Certain products will ...

31 FEATURES Instrument Cluster Indicators Check Engine Indicator This indicator appears if an EFI-related fault occurs. Do not operate the snowmobile if this warning appears. Serious engine damage could result. See your dealer. See page 44 for diagnostic code definitions. Over-Temperature Indicator ...

32 FEATURES Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. The center displays vehicle speed, engine speed, odometer, resettable trip meters (2), total engine hours of operation, fuel level, engine tempera-ture and diagnostic display mo...

33 FEATURES 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 34. 2. Speed Display - The s...

34 FEATURES Instrument Cluster Rider Information Center Speed Display Area The speed display area displays either vehicle speed or engine speed. Vehicle speed is displayed in either miles per hour (MPH) or kilometers per hour (km/h). Engine speed is displayed in revolutions per minute (RPM). 1. To c...

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

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

38 FEATURES 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 POLARIS de...

40 FEATURES 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 displayed. I...

41 FEATURES 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 release SEL ...

42 FEATURES 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 Secu-rity System procedure beginning on pag...

43 FEATURES 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 and a di...

44 FEATURES Instrument Cluster Rider Information Center Diagnostic Display Code Definitions Open Load: There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed. Short-to-Ground: The wire is shorted to ground between the electronic co...

46 THE PERFECT FIT Suspension Quick Set-Up Guide The suspension on your RUSH is incredibly easy to adjust to your weight and riding style. Just remember three simple steps: 1. Set up rear shock spring preload for rider weight. 2. Adjust the rear spring to tune vehicle balance (ski pressure and weigh...

47 THE PERFECT FIT Suspension Quick Set-Up Guide Step 2: Adjust the rear spring to tune vehicle balance. After the initial test ride, make adjustments to the rear shock spring to improve vehicle balance. Increasing preload will increase ski pressure and result in less weight transfer, flatter corner...

48 THE PERFECT FIT Suspension Quick Set-Up Guide Accessory rear shock springs are available for riders of different weights. A corresponding gauge is available for each spring type. The gauge provided with your snowmobile is calibrated for the stock spring, which should be used by most riders. Do no...

49 THE PERFECT FIT Suspension Quick Set-Up Guide POLARIS recommends that riders use this Quick Set-Up Guide to make any adjustments for rider weight and trail conditions. If additional tun-ing is needed after you have exhausted all possible adjustments to the rear shock spring and clicker, refer to ...

50 THE PERFECT FIT Front Suspension Adjustments Independent Front Suspension (IFS) Factory settings, combined with user adjustments to the rear shock spring, should be all that’s necessary to provide the best riding experi-ence for most riders. If all rear shock spring adjustments have been exhauste...

51 THE PERFECT FIT Front Suspension Adjustments IFS Shock Spring Preload Increasing spring preload will increase ski-to-ground pressure. Decreasing spring pre-load will decrease ski-to-ground pressure. When adjusting, be sure the springs on both the left and right sides of the machine are at the sam...

52 THE PERFECT FIT Front Suspension Adjustments IFS Shock Compression Damping Make adjustments to the shock clickers to control bottoming. Make the adjustments in 1-to-2-click increments, then test ride. Repeat the adjust-ment until the desired result is achieved. TIP: Initially, heavier riders may ...

53 THE PERFECT FIT Rear Suspension Adjustments Rider weight, riding style, trail conditions, and vehicle speed all affect suspension action. Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. However, all sus-pension designs...

54 THE PERFECT FIT Rear Suspension Adjustments Front Track Shock Compression Damping Make adjustments to the shock clicker to control bottoming. Make the adjustments in 2-click incre-ments, then test ride. Repeat the adjustment until the desired result is achieved. TIP: Initially, heavier riders may...

55 THE PERFECT FIT Rear Suspension Adjustments Rear Shock Spring Preload Settings Make adjustments to the rear shock spring to tune vehicle balance. Always perform shock spring preload adjustments with the weight of the vehicle removed from the shock and with the shock at full extension. Increasing ...

56 THE PERFECT FIT Handlebar Adjustments Handlebar Position 1. Loosen the four bolts on the bottom of the adjuster block. If necessary, pry the blocks apart with a screw-driver. 2. Adjust the handlebar for- ward or rearward to the desired position. 3. Tighten the bolts. Torque the bolts to 13-16 ft....

57 THE PERFECT FIT Accessories POLARIS offers a wide range of accessories for your snowmobile to help make each ride more enjoyable. Use only POLARIS parts and accessories on your POLARIS snowmo-bile. Use of unapproved parts and accessories may result in: • Non-compliance with government/industry re...

58 THE PERFECT FIT Traction Products Studs 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 use of any non-POLARIS traction products. Use only POLARIS-approved traction products on your snowmobile. If you c...

59 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 vehicle s...

61 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 follow-ing items on a weekly basis or be...

62 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 ...

63 PRE-RIDE INSPECTIONS Before Starting the Engine Brakes Always check the following items for proper operation before starting the engine. Brake Lever Travel Squeeze the brake lever. It should move no closer to the handgrip than 1/2 inch (1.3 cm). A smaller distance indi-cates low brake fluid level...

64 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. Parking Brake Lever Lock 3. Master Cylin...

65 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...

66 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...

67 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 ON position. 2. Pull the engine stop switch up to the...

68 OPERATION Break-In Period Engine Break-In Always follow these recommended break-in procedures for new or rebuilt engines. The first tank of fuel is considered the break-in period for the engine. Premix the first tank of fuel and fill the oil reservoir as outlined below. Oil added to the fuel and ...

69 OPERATION Break-In Period Engine Break-In 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 extended periods during the first three hours of use. Vary the throttle openings and vehicle speeds...

70 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...

72 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...

73 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 68 for oil recommendations. 1. Immediately stop the engine if the low oil indicator light comes on. 2. Open the left side panel. 3. View the oil level in the...

74 OPERATION Engine Stop Switch Push down on the engine stop switch (X) to ground out the ignition and stop the engine quickly. Pull the switch up to the ON position to allow restart-ing. Throttle Safety Switch The throttle safety switch is designed to stop the engine whenever all pressure is remove...

75 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...

76 OPERATION Emergency Stopping The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 74 for more information about the engine stop switch and throttle safety switch. SYSTEM WHAT IT DOES Ignition Switch Interrupts ignition circuit Brake Slows jackshaft ...

78 OPERATION 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 sec- ond, then release. The engine will automatically reduce RPM and star...

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

80 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 con-trol information (ECI) la...

81 MAINTENANCE POLARIS Recommended Maintenance Program To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as out-lined in this manual. Record maintenance and service in the Mainte-nance Log beginning on page 133. The recomme...

82 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...

84 MAINTENANCE Periodic Maintenance Interval Table I - Inspect (clean, adjust, tighten, lubricate, replace if necessary)C - Clean R - Replace L - Lubricate Bolt Torque Inspection To maintain proper chassis performance, see your POLARIS dealer for a bolt torque inspection every 1000 miles (1600 km). ...

85 MAINTENANCE Hood/Side Panel The hood and side panels of the snowmobile protect the operator from moving parts. Never oper-ate a snowmobile with the side panels open or removed. Always ensure that the hood and side panels are securely in place before starting the engine. To open a side panel, rota...

86 MAINTENANCE Lubrication Chaincase Oil Check and change the chaincase oil at the intervals outlined in the main-tenance charts beginning on page 81. Maintain the oil level at the top of the fill plug hole. POLARIS recommends the use of POLARIS Syn-thetic Chaincase Lube. See page 115 for the part n...

87 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. Fuel Pump All fuel pump service must be performed by an authorized POLARIS dealer. Do not at...

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

89 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. CAUTIO...

90 MAINTENANCE Oil Lines Inspect oil line condition every 1000 miles (1600 km). Oil Filter Please see your dealer for replacement of the in-line oil filter every 2000 miles (3200 km) as outlined in the maintenance charts beginning on page 81.

91 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 oper-ated at extremely low temperatures, greater pr...

92 MAINTENANCE Cooling System Engine Overheating The over-temperature indicator on the instrument cluster will illuminate when the engine is overheating. The indicator will flash when engine temperature reaches critical levels. Illuminated Indicator Take action to cool the engine: • Drive in loose s...

93 MAINTENANCE Cooling System Bleeding the Cooling System CAUTION! Steam and hot liquids will cause burns to your skin. Never bleed the cooling system or remove the pressure cap when the engine is warm or hot. Use of a non-standard pressure cap will not allow the recovery system to function properly...

94 MAINTENANCE Exhaust System Check the exhaust system for wear or damage at approximately 2000 miles (3200 km). Always allow the engine and exhaust system to cool completely before inspecting. CAUTION! Hot exhaust system parts can cause burns. Allow adequate time for the exhaust system to cool. Nev...

95 MAINTENANCE Drive Chain Tension Check drive chain tension at the intervals outlined in the maintenance charts beginning on page 81 and before each long trip. 1. Remove the side panels. 2. Rotate the driven clutch coun- ter-clockwise to move all chain slack to the tensioner side. Lock the brake le...

96 MAINTENANCE Brakes Hydraulic Brake Inspection Inspect the brake lever reserve before each use of the snowmobile. See page 63. Brake pads must be replaced when the brake pad material becomes thin-ner than the backing plate (approximately 1/16 inch or 1.5 mm). A kit is available for replacing brake...

97 MAINTENANCE Brakes Brake Fluid The brake fluid level can be seen through a plastic sight glass in the brake reservoir. If the fluid is sufficient, the sight glass will be black. If the sight glass is any color other than black, add brake fluid. Replace brake fluid at least every two years with PO...

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

99 MAINTENANCE Lights When servicing a halogen lamp, avoid touching the lamp with bare fin-gers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do touch a lamp, clean it with denatured alcohol. Headlight Lamp Replacement 1. Remove the wire ...

100 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...

101 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...

102 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 Adjust...

103 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 ...

104 MAINTENANCE Clutch System Drive Belt Installation 1. Drop the drive belt over the drive clutch and pull back the slack. The belt cord line should be flush with, or slightly above, the outer cir-cumference of the driven clutch sheaves. The belt will seat itself in the driven clutch during the bre...

105 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 ...

106 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 ...

107 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 106. If the track needs adjustment: 6. Loosen the rear idler shaft bolt. 7. Loosen the locknuts. 8. Tighten or...

108 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...

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

110 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 camber adjustment. See your POLARIS dealer. 1. Place the handlebars in a straight-ahead ...

111 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...

112 MAINTENANCE Steering System 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). Rear...

113 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...

114 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...

115 POLARIS PRODUCTS Part No. Description Engine Lubricants 2870791 Fogging Oil (12 oz. Aerosol) 2877882 VES 2-Cycle Oil (qt./.95 l) 2877953 VES 2-Cycle Engine Oil (2 qt./1.9 l) 2877883 VES 2-Cycle Engine Oil (gal./3.8 l) 2877884 VES 2-Cycle Engine Oil (2.5 gal./9.5 l) Chaincase Lubricants 2873105 S...

116 SPECIFICATIONS 600 RUSH Capacities and Dimensions Body Style PRO-RIDE Rider Capacity 1 Coolant Capacity 5 qts. (4.7 l) Chaincase Oil Capacity 9 oz. (266.2 ml) Fuel Tank Capacity 11 gal. (41.6 l) Gearcase Oil Capacity (oz./ml) N/A Height 46 inches (117 cm) Length 108 inches (274 cm) Oil Capacity ...

117 SPECIFICATIONS 600 RUSH (Non-Electric Start Models) 600 RUSH (Electric Start Models) 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 (1321...

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

123 TROUBLESHOOTING Suspension Troubleshooting Problem Solution Rear suspension bottoms too easily • Adjust rear shock spring (see pages 47 and 55).• Change rear shock spring (see your dealer).• Revalve rear track shock (see your dealer). Rides too stiff in rear • Check for binding suspension shafts...

124 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. Insufficient warm-up • Warm the engine at least five minutes. Take the drive belt off the snowmobile in extremely cold wea...

125 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 war-ranty. Your dealer receives frequent updates o...

126 WARRANTY Limited Warranty POLARIS Sales Inc., 2100 Highway 55, Medina, MN 55340, provides a ONE YEAR LIMITED WARRANTY on all components of the POLARIS snowmobile against defects in material or workmanship. Warranty period will vary regionally. This warranty covers the parts and labor charges for...

128 WARRANTY Conditions and Exclusions In order to qualify for warranty, the product must have been properly set up and tested by a POLARIS Dealer (if applicable). Failure of any dealer to perform the required vehi-cle Pre-Delivery Inspection, perform all applicable service bulletins and have the co...

129 WARRANTY Exported Vehicles EXCEPT WHERE SPECIFICALLY REQUIRED BY LAW, THERE IS NO WAR-RANTY OR SERVICE BULLETIN COVERAGE ON THIS VEHICLE IF IT IS SOLD OUTSIDE THE COUNTRY OF THE SELLING DEALER'S AUTHORIZED LOCA-TION. This policy does not apply to vehicles that have received authorization for exp...

130 WARRANTY Exported Vehicles How to Get Service If You Move: If you move to another country, be sure to contact POLARIS Customer Assistance and the customs department of the destination country before you move. Vehicles importa-tion rules vary considerably from country to country. You may be requi...

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

136 INDEX A Accessories . . . . . . . . . . . . . . . . . . . . 57Air Pollution . . . . . . . . . . . . . . . . . . . . 6Avalanches. . . . . . . . . . . . . . . . . . . . . 15 B Belt Break-In . . . . . . . . . . . . . . . . . . . 69Brake Lever Travel Inspection . . . . . 63Brakelight Replacement. . ...