2010-12 600 800 Rush Switchback RMK Service Manual PDF

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
SNOWMOBILE NUMBER DESIGNATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.40
MODEL NUMBER DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.40
VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.40
VIN NUMBER DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.40
TUNNEL DECAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.41
PUBLICATION PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.41
2010 PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.41
2011 PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.41
2012 PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.42
SERVICE/SAFETY BULLETINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.42
GENERAL REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.43
STANDARD BOLT TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.43
METRIC BOLT TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.43
GASOLINE VOLATILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.44
FUEL / OIL PREMIX RATIOS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.44
FUEL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.44
SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.45
METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.45
DECIMAL EQUIVALENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.45
MEASUREMENT CONVERSION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.46
PISTON WASH / SPARK PLUG READING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.46
GLOSSARY OF TERMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.47
9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

1.1
2011 Polaris Sales Inc.
General Information
MODEL SPECIFICATIONS Clutch Settings
ALTITUDE DRIVE CLUTCH P2 DRIVEN CLUTCH

2010 600 RUSH meters Shift Clutch Clutch Driven
(feet) Gearing
Weight Spring Spring Helix
Model Numbers: 0-600
S10BF6KSA / S10BF6KSL / S10BF6KEA 10-64 23:39 - 72
(0-2000)
600-1200
10-62 22:39 - 72
Engine (2000-4000)
1200-1800
Liberty Liquid-Cooled / 10-60 BLACK 130 - 180
(4000-6000)
Engine Type 120 - 310 Tabbed
58/42 - .45
22:40 - 72
Case Reed Induction 1800-2400 7043601 7043515
5137176
10-58
(6000-8000)
Model Number S4202-6044-OP6N
2400-3000
10-56
Displacement / # Cylinders 599cc / 2 (8000-10,000)
20:41 - 72
3000-3600
Bore (inches/mm) 3.04 / 77.25 (10,000-12,000)
10A-L
Stroke (inches/mm) 2.52 / 64 Drive Clutch Bolt Torque: 80 lb.ft. (108Nm)

Piston to Cylinder Re-torque after running engine.
.0033-.0054 / 0.085-0.137
Clearance (inches/mm)
Clutch Settings (Electric Start Models)
Installed Ring Gap
.014-.020 / 0.356 - 0.508
(inches / mm) ALTITUDE DRIVE CLUTCH P2 DRIVEN CLUTCH
meters Shift Clutch Clutch Driven
Operating RPM 200 8250 (feet) Weight Spring Spring Helix
Gearing
Idle RPM 1700 0-600

10-64 23:39 - 72
(0-2000)
Engagement RPM 200 3800
600-1200
10-62 22:39 - 72
Exhaust Valve Spring Purple (2000-4000)
1200-1800
Thermostat Opening (4000-6000)
10-60 BLK/GRN 130 - 180
120 / 49 58/42 - .45
Temperature ( F/ C) 1800-2400
120 - 340 Tabbed
5137176
22:40 - 72
10-58 7042083 7043515
(6000-8000)
Fuel Delivery 2400-3000
10-56
(8000-10,000)
20:41 - 72
Type - Number of Fuel 3000-3600
DC-CFI - 4 10A-L
Injectors (10,000-12,000)
Throttle Body Marking 1203978 Drive Clutch Bolt Torque: 80 lb.ft. (108Nm)
Re-torque after running engine.
Throttle Body Bore 46mm
TPS Voltage @ Idle NOTE: OPTIONAL - USE 2 GRAM LIGHTER CLUTCH
0.95 +/- 0.01 VDC WEIGHTS WHEN OPERATING IN PROLONGED
(5 VDC +/- .01 Input)
WARM TEMPERATURES (LATE FALL/SPRING
Fuel Pressure - PSI (bar) 58-60 (4.0-4.1)
SEASON) TO MAINTAIN PEAK OPERATING RPM.
Fuel Octane (R+M/2)
10% Ethanol 24 Resistor <91 Octane Track
(Non-Oxygenated)
OR Width - Inches (cm) 15 (38)
87/89/91+ Length - Inches (cm) 120 (304.8)
(Up to10% Oxygenated)
Pitch 2.86
Plies 2
Premium/Non-Ethanol 91+
160 Resistor (Non-Oxygenated) Lug Height - Inches (cm) 1.25 (3.175) (Ripsaw)
Track tension sag in/cm
with 10 lbs/4.54kg placed
7/8 - 1-1/8 (2.2 - 2.9cm)
16 in/40cm ahead of rear
idler shaft
1.2 9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

General Information
General Rear Suspension
Width (in/cm) 48 / 121.9 Suspension Type Pro-Ride Progressive 1
Length (in/cm) 108 / 274 Walker Evans w/Remote Reservoir
Front Track Shock
Height (in/cm) 46 / 117 16 Click Compression Adjustable
(FTS)
Factory Setting** = 2
Estimated Dry Weight (lb/kg) 459 / 208
FTS Spring Rate
Fuel (Gallons / Liters) 11 / 41.6 120 - 310 (21 - 54.25)
lbs/in (N/mm)
Oil (Quarts / Liters) 3.4 / 3.3 FTS Spring Installed
Preload = .75 (1.9)
Cooling System Capacity(Qts/ L) 5.25 / 5.0 Length
7.75 (19.7)
Inches (cm)
Brake Fluid DOT 4
Walker Evans Needle
Drive Belt
Rear Track Shock w/Remote Reservoir
Part Number 3211122
(RTS) 16 Click Compression Adjustable
Width (inches / cm) 1.460 / 3.7
Side Angle 26_
Circumference (inches / cm) 46.77 / 118.8 Standard RTS Spring PN: 7043572-385
Center Distance (inches / cm) 11.5 / 29.2 Rider Weight*
120 - 250lbs.
Chaincase
Rate lbs/in (N/mm) 190 (33.25)
Center Distance (inches) 7.53
Top Gear (Stock) 23 LW RTS Spring PN: 7041575-385
Bottom Gear (Stock) 39 Rider Weight*
Chain (Stock) 72 90 - 150lbs.
Gear Lube Polaris Synthetic (80W) Rate lbs/in (N/mm) 120 (21)
Capacity (oz / ml) 9 / 266 HD RTS Spring PN: 7043585-385
Reverse System PERC Rider Weight*
240 - 335+lbs.
Electrical Rate lbs/in. (N/mm) 260 (45.5)
Alternator Output Spring length set to rider weight
Operating Voltage 13.5 - 14.5 VDC using adjustment gauge.
Watts @ 13.5 VDC (Total) 400 STD Gauge PN: 5253792
LW Gauge PN: 5253854
18_ @1700 RPM HD Gauge PN: 5253855
Ignition Timing
Coolant Temp = 120_F (49_C) (STD gauge in tool kit. LW and HD
RTS Spring
Spark Plug Gap in.(mm) .027 (.70) gauges are accessories and should
Rider / Weight Setting
Spark Plug NGK BPR9ES be ordered when ordering a LW or
HD spring.)
Rider weight adjustment can also be
Front Suspension
performed using tape measure and
Suspension Type PRO-RIDE RTS Spring Guide Table located in
the Steering/Suspension Chapter.
Walker Evans Needle w/Remote
Reservoir Rear Travel
Shocks 14 (35.6)
16 Click Compression Adjustable Inches (cm)
NOTE: * = Rider weight in everyday clothing.
IFS Spring Rate
80 (14) ** = From full soft (CCW) position.
lbs/in (N/mm)
IFS Spring Installed Preload = 3.75 (9.5)
Length - Inches (cm) 10.25 (26)
Front Vertical Travel
9 (22.9)
Inches (cm)
Ski Center Distance
Inches (cm) 42.5 (108)
Setup Width 41.52 (105)
Camber Inches (cm) 1.68 0.31 (4.3 .8)
Toe Out Inches (mm) 0 -1/8 (0 - 3)

1.3
General Information
2011 600 RUSH Clutch Settings
DRIVE CLUTCH P2 DRIVEN CLUTCH
Model Numbers: ALTITUDE
600 RUSH (feet) Weight Spring Spring Helix
Gearing
S11BF6NSA / S11BF6NSL / S11BF6NSB / S11BF6NSM
0-600
10-64 23:39 - 72
(0-2000)
600 RUSH LX 600-1200
10-62 22:39 - 72
S11BD6NSL / S11BD6NSM (2000-4000)
1200-1800
10-60 BLACK 130 - 180
(4000-6000)
600 RUSH PRO-R 120 - 310 Tabbed
58/42 - .45
22:40 - 72
1800-2400 5137176
S11BP6NSA / S11BP6NSL / S11PB6NEL / S11BP6NSB (6000-8000)
10-58 7043681 7043515
S11BP6NSM / S11BE6NSM
2400-3000
10-56
(8000-10,000)
Engine 20:41 - 72
3000-3600
10A-L
(10,000-12,000)
Liberty Liquid-Cooled /
Engine Type Drive Clutch Bolt Torque: 80 lb.ft. (108Nm)
Case Reed Induction
Model Number S4215-6044-OO6N
Displacement / # Cylinders 599cc / 2 Clutch Settings (Electric Start Models)
Bore (inches/mm) 3.04 / 77.25 ALTITUDE DRIVE CLUTCH P2 DRIVEN CLUTCH
Stroke (inches/mm) 2.52 / 64 (feet) Weight Spring Spring Helix
Gearing
Piston to Cylinder 0-600

.0033-.0054 / 0.085-0.137 10-64 23:39 - 72
Clearance (inches/mm) (0-2000)
600-1200
Installed Ring Gap (2000-4000)
10-62 22:39 - 72
.017-.025 / 0.450-0.650
(inches / mm) 1200-1800
10-60 BLK/GRN 130 - 180
(4000-6000)
Operating RPM 200 8250 120 - 340 Tabbed
58/42 - .45
22:40 - 72
1800-2400 5137176
10-58 7042083 7043515
Idle RPM 200 1700 (6000-8000)
Engagement RPM 200 3800 2400-3000

10-56
(8000-10,000)
20:41 - 72
Exhaust Valve Spring Purple 3000-3600
10A-L
(10,000-12,000)
Thermostat Opening
120 / 49 Drive Clutch Bolt Torque: 80 lb.ft. (108Nm)
Temperature ( F/ C)
Fuel Delivery
NOTE: OPTIONAL - USE 2 GRAM LIGHTER CLUTCH
Type - Number of Fuel WEIGHTS WHEN OPERATING IN PROLONGED
DC-CFI - 4
Injectors WARM TEMPERATURES (LATE FALL/SPRING
Throttle Body Marking 1203978 SEASON) TO MAINTAIN PEAK OPERATING RPM.
Throttle Body Bore 46mm Track

TPS Voltage @ Idle
0.95 +/- 0.01 VDC Width - Inches (cm) 15 (38)
(5 VDC +/- .01 Input)
Length - Inches (cm) 121 (307)
Pitch 2.52
Fuel Octane (R+M/2)
Plies 2
10% Ethanol 24 Resistor <91 Octane
(Non-Oxygenated) Lug Height - Inches (cm)
OR RUSH 1.0 (2.54) (Hacksaw)
87/89/91+ RUSH PRO-R 1.25 (3.175) (Ripsaw)
(Up to10% Oxygenated) Track tension sag in/cm
Premium/Non-Ethanol 91+ 1/2 - 1.0 (1.3 - 2.54cm)
160 Resistor (Non-Oxygenated) idler shaft

General Information
Width (in/cm) 48 / 121.9 Suspension Type PRO-RIDE Progressive 1
Length (in/cm) 108 / 274 Front Track Shock
Height (in/cm) 46 / 117 (FTS)
RUSH Fox HPG w/IFP
Estimated Dry Weight (lb/kg) 469 / 212 RUSH PRO-R Walker Evans w/Remote Reservoir
Fuel (Gallons / Liters) 11 / 41.6 16 Click Compression Adjustable
Oil (Quarts / Liters) 3.4 / 3.3
FTS Spring Rate
Cooling System Capacity(Qts/ L) 6 / 5.7 120 - 310 (21 - 54.25)
lbs/in (N/mm)
Brake Fluid DOT 4
FTS Spring Installed
Drive Belt Length-Inches (cm) 7.5 (19.05)
Part Number 3211122 RUSH Preload 1.0 (2.54)
Width (inches / cm) 1.460 / 3.7 RUSH PRO-R Preload 1.0 (2.54)
Side Angle 26_
Rear Track Shock
Circumference (inches / cm) 46.77 / 118.8
(RTS)
Center Distance (inches / cm) 11.5 / 29.2
RUSH Fox HPG w/IFP
Chaincase RUSH PRO-R Walker Evans Needle
Center Distance (inches) 7.53 w/Remote Reservoir
Top Gear (Stock) 23 16 Click Compression Adjustable
Bottom Gear (Stock) 39 Factory Setting** = 4
Chain (Stock) 72
Standard RTS Spring PN: 7043572-133
Gear Lube Polaris Synthetic (80W)
Rider Weight*
Capacity (oz / ml) 9 / 266
120 - 250lbs.
Reverse System PERC
Electrical LW RTS Spring PN: 7041575-385
Rider Weight*
Alternator Output 90 - 150lbs.
Operating Voltage 13.5 - 14.5 VDC Rate lbs/in (N/mm) 120 (21)
Watts @ 13.5 VDC (Total) 400 HD RTS Spring PN: 7043585-385
18_ @1700 RPM Rider Weight*
Ignition Timing
Coolant Temp = 120_F (49_C) 240 - 335+lbs.
Spark Plug Gap in.(mm) .027 (.70) Rate lbs/in. (N/mm) 260 (45.5)
Spark Plug NGK BPR9ES Spring length set to rider weight

using adjustment gauge.
STD Gauge PN: 5254748
Front Suspension
Suspension Type PRO-RIDE HD Gauge PN: 5254750
(STD gauge in tool kit. LW and HD
Shocks RTS Spring
gauges are accessories and should
RUSH Fox HPG w/IFP Rider / Weight Setting
be ordered when ordering a LW or
RUSH PRO-R Walker Evans Needle Piggyback HD spring.)
16 Click Compression Adjustable Rider weight adjustment can also be
Factory Setting** = 6 performed using tape measure and
IFS Spring Rate RTS Spring Guide Table located in
100 (17.5)
lbs/in (N/mm) the Steering/Suspension Chapter.
Spring Preload - Rear Travel
4.5 (11.4) 14 (35.6)
Inches (cm) Inches (cm)
Travel-Inches (cm) 9 (22.9)
Ski Center Distance
** = From full soft (CCW) position.
Inches (cm) 42.5 (108)
Camber Inches (cm) 1.68 0.31 (4.3 .8)

1.5
General Information
DRIVE CLUTCH DRIVEN CLUTCH
Gearing
S11BF8GSA / S11BF8GSL / S11BF8GSB / S11BF8GSM
0-600
10-66
(0-2000)
800 RUSH LX 600-1200
BLU/BLK
10-64 123-203
S11BD8GSM (2000-4000) BLACK
7043064
120-310 22:36-70
1200-1800 7043681
10-62
(4000-6000)
800 RUSH PRO-R 64/42 - .36
1800-2400 5135401
S11BP8GSA / S11BP8GSL / S11PB8GEL / S11BP8GSB (6000-8000)
S11BP8GSM / S11BP8GEM / S11BE8GSM 10-60 BLK/PUR
2400-3000
BLACK 160-240
(8000-10,000)
7043363
Engine 140-330 20:38-70
3000-3600 7043342
10-58
(10,000-12,000)
Case Reed Induction
Model Number S4139-8044-OO8G
Displacement / # Cylinders 794cc / 2 NOTE: OPTIONAL - USE 2 GRAM LIGHTER CLUTCH
WEIGHTS WHEN OPERATING IN PROLONGED
Bore (inches/mm) 3.34 / 85
Stroke (inches/mm) 2.75 / 70 SEASON) TO MAINTAIN PEAK OPERATING RPM.
Piston to Cylinder
.004-.0055 / 0.103-0.141 General
Installed Ring Gap Width (in/cm) 48 / 121.9
.017-.025 / 0.450-0.650
(inches / mm) Length (in/cm) 108 / 274
Operating RPM +0-300 8250 Height (in/cm) 46 / 117
Idle RPM 200 1700 Estimated Dry Weight (lb/kg) 465 / 211
Engagement RPM 200 3800 Fuel (Gallons / Liters) 11 / 41.6
Exhaust Valve Spring Orange Oil (Quarts / Liters) 3.4 / 3.3
Thermostat Opening Cooling System
120 / 49 6 / 5.7
Temperature ( F/ C) Capacity(Qts/ L)
Fuel Delivery Brake Fluid DOT 4

Drive Belt
Type - Number of Fuel Part Number 3211115
DC-CFI - 2
Injectors Width (inches / cm) 1.460 / 3.7
Throttle Body Marking 1204094 Side Angle 26_
Throttle Body Bore 48mm Circumference (inches / cm) 46.77 / 118.8
TPS Voltage @ Idle
0.94 +/- 0.01 VDC Chaincase
(5 VDC +/- .01 Input)
Fuel Pressure - PSI (bar) 58-60 (4.0-4.1) Top Gear (Stock) 22
Fuel Octane (R+M/2) Bottom Gear (Stock) 36
10% Ethanol 24 Resistor <91 Octane Chain (Stock) 70
(Non-Oxygenated) Gear Lube Polaris Synthetic (80W)
OR Capacity (oz / ml) 9 / 266
87/89/91+ Reverse System PERC
160 Resistor (Non-Oxygenated)

General Information
Track Rear Suspension
Width - Inches (cm) 15 (38) Suspension Type PRO-RIDE Progressive 1

Length - Inches (cm) 121 (307) Front Track Shock
(FTS)
Pitch 2.52 RUSH Fox HPG w/IFP
Plies 2 RUSH PRO-R Walker Evans w/Remote Reservoir
Lug Height - Inches (cm) 16 Click Compression Adjustable
RUSH 1.0 (2.54) (Hacksaw) Factory Setting** = 2
RUSH PRO-R 1.25 (3.175) (Ripsaw) FTS Spring Rate
120 - 310 (21 - 54.25)
lbs/in (N/mm)
with 10 lbs/4.54kg placed FTS Spring Installed
1/2 - 1.0 (1.3 - 2.54cm) Length-Inches (cm) 7.5 (19.05)
idler shaft RUSH Preload 1.0 (2.54)
RUSH PRO-R Preload 1.0 (2.54)
Electrical Rear Track Shock
(RTS)
Alternator Output RUSH Fox HPG w/IFP
Operating Voltage 13.5 - 14.5 VDC RUSH PRO-R Walker Evans Needle
Watts @ 13.5 VDC (Total) 400 w/Remote Reservoir
18_ @1700 RPM 16 Click Compression Adjustable
Ignition Timing Factory Setting** = 4
Coolant Temp = 120_F (49_C)
Spark Plug Gap in.(mm) .027 (.70) Standard RTS Spring PN: 7043572-133
Rider Weight*
Spark Plug NGK BPR9ES 120 - 250lbs.
Front Suspension
LW RTS Spring PN: 7041575-385
Suspension Type PRO-RIDE Rider Weight*
90 - 150lbs.
Shocks
Rate lbs/in (N/mm) 120 (21)
RUSH Fox HPG w/IFP
RUSH PRO-R Walker Evans Needle Piggyback HD RTS Spring PN: 7043585-385
16 Click Compression Adjustable Rider Weight*
Factory Setting** = 6 240 - 335+lbs.
Rate lbs/in. (N/mm) 260 (45.5)
IFS Spring Rate
100 (17.5) Spring length set to rider weight
lbs/in (N/mm)
Spring Preload -
4.5 (11.4) STD Gauge PN: 5254748
Inches (cm)
Travel-Inches (cm) 9 (22.9) HD Gauge PN: 5254750
Ski Center Distance (STD gauge in tool kit. LW and HD
RTS Spring
Inches (cm) 42.5 (108) gauges are accessories and should
Rider / Weight Setting
Setup Width 41.52 (105) be ordered when ordering a LW or
HD spring.)
Camber Inches (cm) 1.68 0.31 (4.3 .8) Rider weight adjustment can also be
Toe Out Inches (mm) 0 -1/8 (0 - 3) performed using tape measure and
RTS Spring Guide Table located in
the Steering/Suspension Chapter.
Rear Travel
14 (35.6)
Inches (cm)


1.7
General Information
2011 800 Switchback Assault 800 Switchback Assault 1.3 Clutch Settings
800 Switchback Assault 1.3 (feet) Weight Spring Spring Helix
Gearing
S11CW8GSA / S11CW8GSB / S11CW8GEA
0-600
S11CW8GEB (0-2000)
10-66
BLU/BLK
600-1200
10-64 123-203 23:39 - 72
800 Switchback Assault 2.0 (2000-4000) BLACK
7043064
120-310
S11CW8GST 1200-1800
10-62 7043681
(4000-6000) 64/42 - .36
5135401
Engine 1800-2400
21:40 - 72
(6000-8000)
10-60 BLK/PUR
Liberty Liquid-Cooled / 2400-3000
Engine Type (8000-10,000) BLACK 160-240
Case Reed Induction 140 - 330 7043363 20:42 - 72
3000-3600 7043342
Model Number S4229-8044-OO8G 10-58
(10,000-12,000)
Displacement / # Cylinders 794cc / 2 Drive Clutch Bolt Torque: 80 lb.ft. (108Nm)

Stroke (inches/mm) 2.75 / 70 800 Switchback Assault 2.0 Clutch Settings
Piston to Cylinder
.004-.0055 / 0.103-0.141 ALTITUDE DRIVE CLUTCH DRIVEN CLUTCH
Clearance (inches/mm) meters Shift Clutch Clutch Driven
(feet) Gearing
Installed Ring Gap Weight Spring Spring Helix
.017-.025 / 0.450-0.650
(inches / mm) 0-600
10-66
(0-2000)
Operating RPM +0-300 8250 600-1200
BLU/BLK
10-64 BLACK 123-203
(2000-4000)
Idle RPM 200 1700 120-310 7043064
1200-1800 7043681
10-62
Engagement RPM 200 3800 (4000-6000) 64/42 - .36
20:42 - 72
1800-2400 5135401
Exhaust Valve Spring Orange
(6000-8000)
10-60
Thermostat Opening 2400-3000
BLK/PUR
120 / 49 BLACK 160-240
Temperature ( F/ C) (8000-10,000)
140-330 7043363
3000-3600 7043342
10-58
(10,000-12,000)
Fuel Delivery
Drive Clutch Bolt Torque: 80 lb.ft. (108Nm)
Type - Number of Fuel Re-torque after running engine.
DC-CFI - 2
Injectors
Throttle Body Marking 1204094 NOTE: OPTIONAL - USE 2 GRAM LIGHTER CLUTCH
Throttle Body Bore 48mm WARM TEMPERATURES (LATE FALL/SPRING
TPS Voltage @ Idle SEASON) TO MAINTAIN PEAK OPERATING RPM.
0.94 +/- 0.01 VDC
(5 VDC +/- .01 Input)
Track
Fuel Octane (R+M/2) Width - Inches (cm) 15 (38)
10% Ethanol 24 Resistor <91 Octane Length - Inches (cm) 144 (365.76)
(Non-Oxygenated)
Pitch 2.52
OR
Plies 2
87/89/91+
(Up to10% Oxygenated) Lug Height - Inches (cm)
1.3 1.352 (3.43) (Cobra)
Premium/Non-Ethanol 91+ 2.0 2.0 (5.08) (Series 4)
160 Resistor (Non-Oxygenated) Track tension sag in/cm
3/8 - 1/2 (1 - 1.3cm)
idler shaft

General Information
General Front Suspension
Width (in/cm) 48 / 121.9 Suspension Type PRO-RIDE 1

Length (in/cm) 126 / 320 Walker Evans Needle Piggyback
Height (in/cm) 48 / 121.9 16 Click Compression
Shocks
Adjustable
Estimated Dry Weight (lb/kg) 457 / 212.7 Factory Setting** = 6
Fuel (Gallons / Liters) 11.5 / 43.5 IFS Spring Rate
100 (17.5)
Oil (Quarts / Liters) 3.4 / 3.3 lbs/in (N/mm)
Cooling System IFS Spring Installed
6.0/5.7 10.0 (25.4)
Capacity(Qts/ L) Length - Inches (cm)
Brake Fluid DOT 4 Front Vertical Travel
9 (22.9)
Drive Belt Inches (cm)
Part Number 3211115 Ski Center Distance
Width (inches / cm) 1.460 / 3.7 Inches (cm) 42.5 (108)
Side Angle 26 Setup Width 41.52 (105)
Circumference (inches / cm) 46.77 / 118.8 Camber Inches (cm) 1.68 0.31 (4.3 .8)
Chaincase
Center Distance (inches) 7.53 Rear Suspension
Top Gear (Stock) 23
Bottom Gear (Stock) 39 Suspension Type Switchback 144 Tipped
Chain (Stock) 72 Walker Evans Piggyback
Gear Lube Polaris Synthetic (80W) Front Track Shock 16 Click Compression
Capacity (oz / ml) 9 / 266 (FTS) Adjustable
Reverse System PERC Factory Setting** = 8
Electrical FTS Spring Rate

170 (21 - 54.25)
lbs/in (N/mm)
Alternator Output
Operating Voltage 13.5 - 14.5 VDC
Length 7.25 (18.4)
Watts @ 13.5 VDC (Total) 400
Inches (cm)
18_ @1700 RPM
Ignition Timing Walker Evans
w/Remote Reservoir
Spark Plug Gap in.(mm) .027 (.70) Rear Track Shock
16 Click Compression
Spark Plug NGK BPR9ES (RTS)
Adjustable
.359/77
Torsion Springs LH=7041629-329
RH=7041630-329
Rear Travel
14.5 (36.8)
Inches (cm)

1.9
General Information
2011 800 RMK 155 Clutch Settings
S11CM8GSA / S11CM8GSL / S11CM8GEA (feet) Weight Spring Spring Helix
Gearing
S11CM8GSB / S11CM8GSM
0-600
10-68
(0-2000)
Engine 600-1200
10-66 BLACK
(2000-4000)
Engine Type 1200-1800 7043063
Case Reed Induction (4000-6000)
10-64 BLACK
56/42 - .36
140 - 330 20:42 - 72
5135403
10-62 7043342
(6000-8000)
Displacement / # Cylinders 794cc / 2 2400-3000
10-60 BLK/PUR
(8000-10,000)
Bore (inches/mm) 3.34 / 85 160-240
3000-3600 7043363
Stroke (inches/mm) 2.75 / 70 10-58
(10,000-12,000)
Piston to Cylinder Drive Clutch Bolt Torque: 80 lb.ft. (108Nm)

.0040-.0055 / 0.103-0.141 Re-torque after running engine.
Installed Ring Gap
.017-.025 / 0.450-0.650 NOTE: OPTIONAL - USE 2 GRAM LIGHTER CLUTCH
(inches / mm)
Operating RPM +0-300 8250 WARM TEMPERATURES (LATE FALL/SPRING
Idle RPM 200 1700 SEASON) TO MAINTAIN PEAK OPERATING RPM.
Engagement RPM 200 3800 General
Width (in/cm) 46.5 / 118.1
Thermostat Opening
120 / 49 Length (in/cm) 129 / 327.7
Temperature ( F/ C)
Height (in/cm) 51 / 129.5
Fuel Delivery Estimated Dry Weight (lb/kg) 440 / 199.6
Type - Number of Fuel Fuel (Gallons / Liters) 11.5 / 43.5
DC-CFI - 2
Injectors Oil (Quarts / Liters) 3.4 / 3.3
Throttle Body Marking 1204094 Cooling System
5.3/5.0
Throttle Body Bore 48mm Capacity(Qts/ L)
TPS Voltage @ Idle Brake Fluid DOT 4
0.94 +/- 0.01 VDC
(5 VDC +/- .01 Input) Drive Belt
Fuel Pressure - PSI (bar) 58-60 (4.0-4.1) Part Number 3211115
Fuel Octane (R+M/2) Width (inches / cm) 1.460 / 3.7
10% Ethanol 24 Resistor <91 Octane Side Angle 26_
(Non-Oxygenated) Circumference (inches / cm) 46.77 / 118.8
OR Center Distance (inches / cm) 11.5 / 29.2
87/89/91+ Chaincase
(Up to10% Oxygenated) Center Distance (inches) 7.53
Top Gear (Stock) 20
Premium/Non-Ethanol 91+ Bottom Gear (Stock) 42
160 Resistor (Non-Oxygenated) Chain (Stock) 72
Reverse System PERC

General Information
Width - Inches (cm) 15 (38) Suspension Type RMK Coil-Over 155 1

Length - Inches (cm) 155 (393.7) Front Track Shock
RydeFX Twin Tube
Pitch 2.86 (FTS)
Plies 1 FTS Spring Rate
150 (26.25)
Lug Height - Inches (cm) 2.4 (6.1) Series 5.1 lbs/in (N/mm)
Track tension sag in/cm Rear Track Shock

RydeAFX Twin Tube
with 10 lbs/4.54kg placed (RTS)
3/8 - 1/2 (1.0 - 1.3cm)
16 in/40cm ahead of rear Standard RTS Spring PN: 7043680-133
idler shaft Rate lbs/in (N/mm) 210 (36.75)
Installed Length In. (cm)
Electrical (Track off ground)
Rider Weight*
Alternator Output
<160lbs./72kg 10-3/4" (27.3)
Operating Voltage 13.5 - 14.5 VDC
160-220lbs./72-99kg 10-1/4" (26)
Watts @ 13.5 VDC (Total) 400
220-280lbs./99-127kg 10-1/8" (25.7)
18_ @1700 RPM 280-340lbs./127-154kg
Ignition Timing 9-3/4" (24.8)
CAUTION: Do not adjust STD
Spark Plug Gap in.(mm) .027 (.70) spring length greater than
Spark Plug NGK BPR9ES 10-3/4" or less than 9-5/8".
HD RTS Spring PN: 7043741-067
Front Suspension Rate lbs/in. (N/mm) 250 (43.75)
Suspension Type PRO-RIDE RMK Adjustable
(Track off ground)
Shocks RydeFX Twin Tube Rider Weight*
IFS Spring Rate 250-300lbs./113-136kg 10-1/8" (25.7)
100 (17.5)
lbs/in (N/mm) 300-350lbs./136-159kg 10" (25.4)
CAUTION: Do not adjust HD
IFS Spring Installed
10.5 (26.7) spring length greater than
Length - Inches (cm)
10-7/8" or less than 9-7/8".
9 (22.9) Rear Travel
Inches (cm) 155 = 16 (40.6)
Inches (cm)
Ski Center Distance
Inches (cm) 39-40-41 (99.1-101.6-104.1) NOTE: * = Rider weight with gear.
Measured inside of spindles.
Camber Inches (cm) 1.95 0.31 (4.3 .8)

1.11
General Information
2011 800 RMK Assault Clutch Settings
S11CN8GSA / S11CN8GSB / S11SN86EA (feet) Weight Spring Spring Helix
Gearing
0-600
Engine (0-2000)
10-68

10-66
Engine Type (2000-4000) BLACK
Case Reed Induction 155-222
1200-1800 7043063
10-64 BLACK
Model Number S4092-8044-OO8G (4000-6000)
140 - 330
56/42 - .36
20:42 - 72
1800-2400 5135403
Displacement / # Cylinders 794cc / 2 10-62 7043342
(6000-8000)
Bore (inches/mm) 3.34 / 85 2400-3000
10-60
(8000-10,000) BLK/PUR
Stroke (inches/mm) 2.75 / 70 160-240
3000-3600 7043363
10-58
Piston to Cylinder (10,000-12,000)
.0040-.0055 / 0.105-0.141
Clearance (inches/mm) Drive Clutch Bolt Torque: 80 lb.ft. (108Nm)
Installed Ring Gap
.017-.025 / 0.450-0.650
(inches / mm)
Operating RPM +0-300 8250 WEIGHTS WHEN OPERATING IN PROLONGED
Idle RPM 200 1700 WARM TEMPERATURES (LATE FALL/SPRING
Exhaust Valve Spring Orange General
Thermostat Opening Width (in/cm) 48 / 121.9
120 / 49
Temperature ( F/ C)
Length (in/cm) 129 / 327.7
Fuel Delivery Height (in/cm) 51 / 129.5
Type - Number of Fuel Estimated Dry Weight (lb/kg) 446 / 202.3

DC-CFI - 2
Injectors Fuel (Gallons / Liters) 11.5 / 43.5
Throttle Body Marking 1204094 Oil (Quarts / Liters) 3.4 / 3.3
Throttle Body Bore 48mm Cooling System
5.3/5.0
TPS Voltage @ Idle Capacity(Qts/ L)
0.94 +/- 0.01 VDC
(5 VDC +/- .01 Input) Brake Fluid DOT 4
Fuel Pressure - PSI (bar) 58-60 (4.0-4.1) Drive Belt
Fuel Octane (R+M/2) Part Number 3211115
10% Ethanol 24 Resistor <91 Octane Width (inches / cm) 1.460 / 3.7
(Non-Oxygenated) Side Angle 26_
OR Circumference (inches / cm) 46.77 / 118.8
87/89/91+ Center Distance (inches / cm) 11.5 / 29.2
(Up to10% Oxygenated) Chaincase
Premium/Non-Ethanol 91+ Top Gear (Stock) 20
160 Resistor (Non-Oxygenated) Bottom Gear (Stock) 42
Chain (Stock) 72
Reverse System PERC

General Information

Walker Evans HPG w/IFP
Pitch 2.86 (FTS)
180 (31.5)
Lug Height - Inches (cm) 2.125 (5.4) (Competition) lbs/in (N/mm)
Track tension sag in/cm FTS Spring Installed

8.50 (21.6)
with 10 lbs/4.54kg placed Length-Inches (cm)
3/8 - 1/2 (1.0 - 1.3cm)
16 in/40cm ahead of rear Walker Evans Needle
idler shaft Piggyback
Rear Track Shock
(RTS)
Electrical Adjustable
Alternator Output
Operating Voltage 13.5 - 14.5 VDC Standard RTS Spring PN: 7043572-133
Watts @ 13.5 VDC (Total) 400 Rate lbs/in (N/mm) 190 (33.25)
18_ @1700 RPM Installed Length In. (cm)
Ignition Timing (Track off ground)
Rider Weight*
Spark Plug Gap in.(mm) .027 (.70)
<160lbs./72kg 10-7/8" (27.6)
Spark Plug NGK BPR9ES 160-220lbs./72-99kg 10-1/4" (26)
220-280lbs./99-127kg 10" (25.4)
Front Suspension 280-340lbs./127-154kg 9-1/2" (24.1)
CAUTION: Do not adjust STD
PRO-RIDE RMK Wide
Suspension Type spring length greater than
Adjustable
11.0" or less than 9-3/8".
Walker Evans Needle Piggyback
16 Click Compression HD RTS Spring PN: 7043740-067
Shocks Rate lbs/in. (N/mm) 250 (43.75)
Adjustable
Factory Setting** = 6 Installed Length In. (cm)
(Track off ground)
IFS Spring Rate Rider Weight*
130 (22.75)
lbs/in (N/mm) 250-300lbs./113-136kg 10-1/8" (25.7)
IFS Spring Installed 300-350lbs./136-159kg 10" (25.4)
10.75 (27.3)
Length - Inches (cm) CAUTION: Do not adjust HD
spring length greater than
9 (22.9) 10-7/8" or less than 9-7/8".
Inches (cm)
Rear Travel
Ski Center Distance 155 = 16 (40.6)
Inches (cm)
Inches (cm) 41.5-42.5-43.5
(105.4-108-110.5)
NOTE: * = Rider weight with gear.
Camber Inches (cm) 2.25 0.31 (5.7 .8)

1.13
General Information
2011 800 PRO RMK 155/163 Clutch Settings
800 PRO RMK 155 (feet) Weight Spring Spring Helix
Gearing
S11CG8GSA / S11CG8GSL / S11CG8GSB
0-600
S11CG8GSM / S11CG8GEA (0-2000)
10-68
600-1200
10-66
800 PRO RMK 163 (2000-4000) BLACK
155-222
S11CH8GSA / S11CH8GSB / S11CH8GEA 1200-1800
10-64 7043063
(4000-6000) BLACK
56/42 - .36
140 - 330 20:42 - 72
5135403
Engine 1800-2400
10-62 7043342
(6000-8000)
Engine Type (8000-10,000)
10-60 BLK/PUR
3000-3600 7043363
(10,000-12,000)

Stroke (inches/mm) 2.75 / 70 NOTE: OPTIONAL - USE 2 GRAM LIGHTER CLUTCH
Piston to Cylinder WEIGHTS WHEN OPERATING IN PROLONGED
.004-.0055 / 0.103-0.141 WARM TEMPERATURES (LATE FALL/SPRING
Installed Ring Gap
.017-.025 / 0.450-0.650
(inches / mm) General
Operating RPM +0-300 8250
Width (in/cm) 46.5 / 118.1
Idle RPM 200 1700
155 = 129/327.7
Engagement RPM 200 3800 Length (in/cm)
163 = 134/340.4
Exhaust Valve Spring Orange Height (in/cm) 51 / 129.5
Thermostat Opening 155 = 431/195.5
120 / 49 Estimated Dry Weight (lb/kg)
Temperature ( F/ C) 163 = 437/198.7
Fuel Delivery Fuel (Gallons / Liters) 11.5 / 43.5

Type - Number of Fuel
DC-CFI - 2 Cooling System 155=5.3/5.0
Injectors
Capacity(Qts/ L) 163=5.5/5.2
Throttle Body Marking 1204094
Brake Fluid DOT 4
Throttle Body Bore 48mm
Drive Belt
TPS Voltage @ Idle Part Number 3211115
0.94 +/- 0.01 VDC
(5 VDC +/- .01 Input) Width (inches / cm) 1.460 / 3.7
Fuel Pressure - PSI (bar) 58-60 (4.0-4.1) Side Angle 26_
Fuel Octane (R+M/2) Circumference (inches / cm) 46.77 / 118.8
10% Ethanol 24 Resistor <91 Octane Center Distance (inches / cm) 11.5 / 29.2
(Non-Oxygenated) Chaincase
OR Center Distance (inches) 7.53
87/89/91+ Top Gear (Stock) 20
(Up to10% Oxygenated) Bottom Gear (Stock) 42
Chain (Stock) 72
Premium/Non-Ethanol 91+ Gear Lube Polaris Synthetic (80W)
160 Resistor (Non-Oxygenated) Capacity (oz / ml) 9 / 266
Reverse System PERC

General Information
Width - Inches (cm) 15 (38)

Suspension Type
RMK Coil-Over 155/163 1
155 (393.7) 163= Tipped Rail
163 (414) Front Track Shock
Pitch 2.86 (FTS)
150 (26.25)

with 10 lbs/4.54kg placed Length 8.50 (21.6)
3/8 - 1/2 (1.0 - 1.3cm) Inches (cm)
idler shaft Rear Track Shock
(RTS)
Electrical Standard RTS Spring PN: 7043714-133
Alternator Output Rate lbs/in (N/mm) 210 (36.75)
Operating Voltage Installed Length In. (cm)
13.5 - 14.5 VDC (Track off ground)
Watts @ 13.5 VDC
400 Rider Weight*
(Total)
<160lbs./72kg 10-3/4" (27.3)
18_ @1700 RPM 160-220lbs./72-99kg 10-3/8" (26.3)
Ignition Timing Coolant Temp = 120_F 220-280lbs./99-127kg 10-1/8" (25.7)
(49_C) 280-340lbs./127-154kg 9-3/4" (24.8)
Spark Plug Gap CAUTION: Do not adjust STD
.027 (.70)
in.(mm) spring length greater than
11.0" or less than 9-3/4".
Spark Plug NGK BPR9ES
Suspension Type PRO-RIDE RMK Adjustable (Track off ground)
Shocks Walker Evans HPG w/IFP Rider Weight*
100 (17.4) 300-350lbs./136-159kg 10" (25.4)
lbs/in (N/mm)
IFS Spring Installed spring length greater than
10.25 (26)
Length - Inches (cm) 10-7/8" or less than 9-7/8".
Front Vertical Travel Rear Travel
9 (22.9) 155/163 = 16 (40.6)
Ski Center Distance
Camber Inches (cm) 1.95 0.31 (4.3 .8)

1.15
General Information
Gearing
S12BF6NSA / S12BF6NSL
0-600
10-64 23:39 - 72
(0-2000)
600 RUSH PRO-R 600-1200
10-62 22:39 - 72
S12BP6NSA / S12BP6NSB / S12BP6NSC / S12BP6NSL (2000-4000)
S12BP6NEL / S12BP6NSM / S12BP6NSP 1200-1800
10-60
(4000-6000) BLACK 130 - 180
58/42 - .45
120 - 310 Tabbed 22:40 - 72
5137176
Engine 1800-2400
10-58 7043681 7043515
(6000-8000)
Engine Type (8000-10,000)
10-56
Case Reed Induction 20:41 - 72
3000-3600
Model Number S4357-6044-OL6N 10A-L
(10,000-12,000)

Bore (inches/mm) 3.04 / 77.25
Stroke (inches/mm) 2.52 / 64 Clutch Settings (Electric Start Models)
Piston to Cylinder
.0033-.0054 / 0.085-0.137 ALTITUDE DRIVE CLUTCH P2 DRIVEN CLUTCH
Clearance (inches/mm) meters Shift Clutch Clutch Driven
(feet) Gearing
Installed Ring Gap Weight Spring Spring Helix
.017-.025 / 0.450-0.650
(inches / mm) 0-600
10-64 23:39 - 72
(0-2000)
Operating RPM 200 8250 600-1200
10-62 22:39 - 72
(2000-4000)
Idle RPM 200 1700
1200-1800
10-60
Engagement RPM 200 3800 (4000-6000) BLK/GRN 130 - 180
58/42 - .45
120 - 340 Tabbed 22:40 - 72
1800-2400 5137176
Exhaust Valve Spring Purple 10-58 7042083 7043515
(6000-8000)
Thermostat Opening 2400-3000
120 / 49 10-56
Temperature ( F/ C) (8000-10,000)
20:41 - 72
3000-3600
10A-L
(10,000-12,000)
Fuel Delivery
Type - Number of Fuel Re-torque after running engine.
DC-CFI - 4
Injectors
Throttle Body Marking 1203978 NOTE: OPTIONAL - USE 2 GRAM LIGHTER CLUTCH
Throttle Body Bore 46mm WARM TEMPERATURES (LATE FALL/SPRING
TPS Voltage @ Idle SEASON) TO MAINTAIN PEAK OPERATING RPM.
0.95 +/- 0.01 VDC
(5 VDC +/- .01 Input)
Track
Fuel Octane (R+M/2) Width - Inches (cm) 15 (38)
10% Ethanol 24 Resistor <91 Octane Length - Inches (cm) 121 (307)
(Non-Oxygenated)
Pitch 2.52
OR
Plies 2
87/89/91+
(Up to10% Oxygenated) Lug Height - Inches (cm)
Base 1.0 (2.54) (Hacksaw)
Premium/Non-Ethanol 91+ PRO-R 1.25 (3.175) (Ripsaw)
160 Resistor (Non-Oxygenated) Track tension sag in/mm
1/4 - 3/8 (6.3 - 9.6mm)
idler shaft

General Information
Height (in/cm) 48 / 121.9 (FTS)
Base Fox HPG w/IFP
Estimated Dry Weight (lb/kg) 469 / 212 PRO-R Walker Evans w/Remote Reservoir
Fuel (Gallons / Liters) 11 / 41.6 16 Click Compression Adjustable
FTS Spring Rate
Cooling System Capacity(Qts/ L) 6 / 5.7 120 - 310 (21 - 54.25)
lbs/in (N/mm)
Brake Fluid DOT 4
Drive Belt Length-Inches (cm) 7.5 (19.05)
Part Number 3211122 Base Preload 1.0 (2.54)
Width (inches / cm) 1.460 / 3.7 PRO-R Preload 1.0 (2.54)
Side Angle 26_
Rear Track Shock
(RTS)
Base Fox HPG w/IFP
Chaincase PRO-R Walker Evans Needle
Center Distance (inches) 7.53 w/Remote Reservoir
Top Gear (Stock) 23 16 Click Compression Adjustable
Bottom Gear (Stock) 39 Factory Setting** = 4
Chain (Stock) 72
Rider Weight*
120 - 260lbs.
Reverse System PERC
Electrical LW RTS Spring PN: 7041575-385
Rider Weight*
Alternator Output 90 - 150lbs.
Operating Voltage 13.5 - 14.5 VDC Rate lbs/in (N/mm) 120 (21)
Watts @ 13.5 VDC (Total) 400 HD RTS Spring PN: 7043585-385
18_ @1700 RPM Rider Weight*
Ignition Timing
Coolant Temp = 120_F (49_C) 240 - 335+lbs.
Spark Plug Gap in.(mm) .027 (.70) Rate lbs/in. (N/mm) 260 (45.5)
Spark Plug NGK BPR9ES Spring length set to rider weight

Front Suspension
RTS Spring
Suspension Type PRO-RIDE (Fixed Camber) Rider / Weight Setting STD gauge supplied with vehicle. LW
and HD springs - Use tape measure
Shocks and RTS Spring Guide Table located
Base Fox HPG w/IFP in the Steering/Suspension Chapter.
PRO-R Walker Evans Needle Piggyback
16 Click Compression Adjustable Rear Travel
14 (35.6)
Factory Setting** = 6 Inches (cm)
IFS Spring Rate
100 (17.5) NOTE: * = Rider weight in everyday clothing.
lbs/in (N/mm)
Preload - Inches (cm)
Base 3.25 (8.25)
PRO-R 2.875 (7.3)
Ski Center Distance
Inches (cm) 42.5 (108)
Camber Inches (cm) NOT ADJUSTABLE

1.17
General Information
Gearing
S12BF8GSA / S12BF8GSL
0-600
10-66
(0-2000)
800 RUSH PRO-R 600-1200
BLU/BLK
10-64 123-203
S12BP8GSA / S12BP8GSB / S12BP8GSC / S12BP8GSL (2000-4000) BLACK
7043064
120-310 22:36-70
S12BP8GEL / S12BP8GSM / S12BP8GSP 1200-1800
10-62 7043681
(4000-6000) 64/42 - .36
5135401
Engine 1800-2400
(6000-8000)
10-60 BLK/PUR
Engine Type (8000-10,000) BLACK 160-240
Case Reed Induction 140-330 7043363 20:38-70
3000-3600 7043342
Model Number S4360-8044-OL8G 10-58
(10,000-12,000)

Stroke (inches/mm) 2.75 / 70 NOTE: OPTIONAL - USE 2 GRAM LIGHTER CLUTCH
Piston to Cylinder WEIGHTS WHEN OPERATING IN PROLONGED
.004-.0055 / 0.103-0.141 WARM TEMPERATURES (LATE FALL/SPRING
Installed Ring Gap
.017-.025 / 0.450-0.650
(inches / mm) General
Operating RPM +0-300 8250
Width (in/cm) 48 / 121.9
Idle RPM 200 1700
Length (in/cm) 108 / 274
Height (in/cm) 46 / 117
Estimated Dry Weight (lb/kg) 465 / 211
Thermostat Opening
120 / 49 Fuel (Gallons / Liters) 11 / 41.6
Temperature ( F/ C)
Fuel Delivery Cooling System
6 / 5.7
Type - Number of Fuel Capacity(Qts/ L)
DC-CFI - 2
Injectors Brake Fluid DOT 4
Throttle Body Marking 1204094 Drive Belt
Throttle Body Bore 48mm Part Number 3211115
Width (inches / cm) 1.460 / 3.7
TPS Voltage @ Idle Side Angle 26_
0.94 +/- 0.01 VDC
(5 VDC +/- .01 Input) Circumference (inches / cm) 46.77 / 118.8
Fuel Pressure - PSI (bar) 58-60 (4.0-4.1) Center Distance (inches / cm) 11.5 / 29.2
Fuel Octane (R+M/2) Chaincase
10% Ethanol 24 Resistor <91 Octane Center Distance (inches) 7.53
(Non-Oxygenated) Top Gear (Stock) 22
OR Bottom Gear (Stock) 36
87/89/91+ Chain (Stock) 70
(Up to10% Oxygenated) Gear Lube Polaris Synthetic (80W)
Premium/Non-Ethanol 91+ Reverse System PERC

General Information

Length - Inches (cm) 121 (307) Front Track Shock
(FTS)
Pitch 2.52 Base Fox HPG w/IFP
Plies 2 PRO-R Walker Evans w/Remote Reservoir
Lug Height - Inches (cm) 16 Click Compression Adjustable
Base 1.0 (2.54) (Hacksaw) Factory Setting** = 2
PRO-R 1.25 (3.175) (Ripsaw) FTS Spring Rate
120 - 310 (21 - 54.25)
lbs/in (N/mm)
Track tension sag in/mm
with 10 lbs/4.54kg placed FTS Spring Installed
1/4 - 3/8 (6.3 - 9.6mm) Length-Inches (cm) 7.5 (19.05)
idler shaft Base Preload 1.0 (2.54)
PRO-R Preload 1.0 (2.54)
Electrical Rear Track Shock
(RTS)
Alternator Output Base Fox HPG w/IFP
Operating Voltage 13.5 - 14.5 VDC PRO-R Walker Evans Needle
Watts @ 13.5 VDC (Total) 400 w/Remote Reservoir
18_ @1700 RPM 16 Click Compression Adjustable
Ignition Timing Factory Setting** = 4
Spark Plug Gap in.(mm) .027 (.70) Standard RTS Spring PN: 7043195-133
Rider Weight*
Spark Plug NGK GR9A-EG 120 - 260lbs.
Front Suspension
Suspension Type PRO-RIDE (Fixed Camber) Rider Weight*
90 - 150lbs.
Shocks
Base Fox HPG w/IFP
PRO-R Walker Evans Needle Piggyback HD RTS Spring PN: 7043585-385
16 Click Compression Adjustable Rider Weight*
Factory Setting** = 6 240 - 335+lbs.
IFS Spring Rate
100 (17.5) Spring length set to rider weight
lbs/in (N/mm)
Preload - Inches (cm)
Base 3.25 (8.25)
RTS Spring
PRO-R 2.875 (7.3)
Rider / Weight Setting STD gauge supplied with vehicle. LW
Travel-Inches (cm) 9 (22.9) and HD springs - Use tape measure
Ski Center Distance and RTS Spring Guide Table located
Inches (cm) 42.5 (108) in the Steering/Suspension Chapter.
Setup Width 41.52 (105) Rear Travel
14 (35.6)
Camber Inches (cm) NOT ADJUSTABLE Inches (cm)

1.19
General Information
2012 800 RUSH PRO-R LE Clutch Settings
S12BV8GSM / S12BV8GEM (feet) Weight Spring Spring Helix
Gearing
0-600
Engine (0-2000)
10-66
BLU/BLK
10-64 123-203
7043064
Case Reed Induction 120-310 22:36-70
1200-1800 7043681
10-62
Model Number S4360-8044-OL8G (4000-6000) 64/42 - .36
1800-2400 5135401
Displacement / # Cylinders 794cc / 2 (6000-8000)
10-60 BLK/PUR
Bore (inches/mm) 3.34 / 85 2400-3000
160-240
(8000-10,000) BLACK
7043363
Stroke (inches/mm) 2.75 / 70 140-330 20:38-70
3000-3600 7043342
10-58
.004-.0055 / 0.103-0.141
Installed Ring Gap
.017-.025 / 0.450-0.650
(inches / mm)
Thermostat Opening Width (in/cm) 48 / 121.9
120 / 49
Temperature ( F/ C)
Length (in/cm) 108 / 274
Fuel Delivery Height (in/cm) 46 / 117
Type - Number of Fuel Estimated Dry Weight (lb/kg) 465 / 211

DC-CFI - 2
Injectors Fuel (Gallons / Liters) 11 / 41.6
6 / 5.7
0.94 +/- 0.01 VDC
Chain (Stock) 70
Reverse System PERC

General Information

Length - Inches (cm) 121 (307) Walker Evans w/Remote
Front Track Shock
Pitch 2.52 Reservoir
(FTS)
Plies 2 16 Click Compression
Adjustable
Lug Height - Inches (cm) 1.352 (3.43) (Cobra) Factory Setting** = 2
Track tension sag in/mm FTS Spring Rate
with 10 lbs/4.54kg placed 120 - 310 (21 - 54.25)
1/4 - 3/8 (6.3 - 9.6mm) lbs/in (N/mm)
idler shaft FTS Spring Installed
Length-Inches (cm) 7.5 (19.05)
Electrical Preload 1.0 (2.54)
Rear Track Shock Walker Evans Needle
Alternator Output (RTS) w/Remote Reservoir
Operating Voltage 16 Click Compression
13.5 - 14.5 VDC
Watts @ 13.5 VDC Adjustable
400
(Total) Factory Setting** = 4
18_ @1700 RPM Standard RTS
Ignition Timing Coolant Temp = 120_F PN: 7043195-133
Spring
(49_C) Rider Weight*
Spark Plug Gap 120 - 260lbs.
.027 (.70) 170 (29.75)
in.(mm) Rate lbs/in (N/mm)
Spark Plug NGK GR9A-EG LW RTS Spring PN: 7041575-385
Rider Weight*
Front Suspension 90 - 150lbs.
Suspension Type PRO-RIDE (Fixed Camber)
Walker Evans Piggyback Rider Weight*
16 Click Compression 240 - 335+lbs.
Shocks
Adjustable / 16 Click Rebound Rate lbs/in. (N/mm) 260 (45.5)
Adjuster
Factory Compression Setting** Spring length set to rider weight
=6 using adjustment gauge.
Factory Rebound Setting = 8 STD Gauge PN: 9923267
RTS Spring
IFS Spring Rate Rider / Weight STD gauge supplied with
80 (14)
lbs/in (N/mm) Setting vehicle. LW and HD springs - Use
Preload - Inches tape measure and RTS Spring
3.25 (8.25)
(cm) Guide Table located in the
Travel-Inches (cm) 9 (22.9) Steering/Suspension Chapter.
Ski Center Distance Rear Travel

14 (35.6)
Inches (cm) 42.5 (108) Inches (cm)
Camber - Inches ** = From full soft (CCW) position.
NOT ADJUSTABLE
(cm)
Toe Out - Inches
0 -1/8 (0 - 3)
(mm)

1.21
General Information
2012 600 Switchback Clutch Settings
600 Switchback (feet) Weight Spring Spring Helix
Gearing
S12BR6NSA / S12BR6NSL
0-600
10-64 23:39 - 72
(0-2000)
600 Switchback Adventure 600-1200
S12BA6NSL 10-62 22:39 - 72
(2000-4000)
1200-1800
10-60 BLACK 130 - 180
600 Switchback PRO-R (4000-6000)
120 - 310 Tabbed
58/42 - .45
22:40 - 72
5137176
S12BS6NSA / S12BS6NSB / S12BS6NSC / S12BS6NSL 1800-2400
10-58 7043681 7043515
(6000-8000)
S12BS6NEL / S12BS6NSM / S12BS6NSP
2400-3000
10-56
(8000-10,000)
Engine 20:41 - 72
3000-3600
10A-L
(10,000-12,000)
Case Reed Induction
Model Number S4357-6044-OL6N
Displacement / # Cylinders 599cc / 2 Clutch Settings (Electric Start Models)
Bore (inches/mm) 3.04 / 77.25 ALTITUDE DRIVE CLUTCH P2 DRIVEN CLUTCH
meters
Stroke (inches/mm) 2.52 / 64 (feet)
Shift Clutch Clutch Driven
Gearing
Weight Spring Spring Helix
Piston to Cylinder
.0033-.0054 / 0.085-0.137 0-600
10-64 23:39 - 72
Clearance (inches/mm) (0-2000)
Installed Ring Gap 600-1200

10-62 22:39 - 72
.017-.025 / 0.450-0.650 (2000-4000)
(inches / mm)
1200-1800
10-60 BLK/GRN 130 - 180
Operating RPM 200 8250 (4000-6000)
120 - 340 Tabbed
58/42 - .45
22:40 - 72
1800-2400 5137176
7042083 7043515
Idle RPM 200 1700 (6000-8000)
10-58
Engagement RPM 200 3800 2400-3000

10-56
(8000-10,000)
Exhaust Valve Spring Purple 20:41 - 72
3000-3600
10A-L
Thermostat Opening (10,000-12,000)
120 / 49
Temperature ( F/ C) Drive Clutch Bolt Torque: 80 lb.ft. (108Nm)
Fuel Delivery
Type - Number of Fuel WEIGHTS WHEN OPERATING IN PROLONGED
DC-CFI - 4
Injectors WARM TEMPERATURES (LATE FALL/SPRING
Throttle Body Marking 1203978 SEASON) TO MAINTAIN PEAK OPERATING RPM.
Throttle Body Bore 46mm Track
TPS Voltage @ Idle
0.95 +/- 0.01 VDC Width - Inches (cm) 15 (38)
(5 VDC +/- .01 Input)
Fuel Pressure - PSI (bar) 58-60 (4.0-4.1) Length - Inches (cm) 136 (345.4)
Fuel Octane (R+M/2) Pitch 2.52

10% Ethanol 24 Resistor <91 Octane Plies 2
(Non-Oxygenated) Lug Height - Inches (cm)
OR Base 1.25 (3.175) (Ripsaw)
87/89/91+ Adventure/PRO-R 1.352 (3.43) (Cobra)
(Up to10% Oxygenated) Track tension sag in/mm
Premium/Non-Ethanol 91+ 1/4 - 3/8 (6.3 - 9.6mm)
160 Resistor (Non-Oxygenated) idler shaft

General Information
Height (in/cm) 46 / 117 (FTS)
Base/Adventure Fox HPG w/IFP
Estimated Dry Weight (lb/kg) 469 / 212 PRO-R Walker Evans w/Remote
Fuel (Gallons / Liters) 11 / 41.6 Reservoir
16 Click Compression Adjustable
Cooling System Capacity(Qts/ L) 5 / 4.7
FTS Spring Rate
Brake Fluid DOT 4 120 - 310 (21 - 54.25)
lbs/in (N/mm)
Drive Belt FTS Spring Installed
Part Number 3211122 Length-Inches (cm) 7.5 (19.05)
Width (inches / cm) 1.460 / 3.7 Base/Adventure Preload 1.0 (2.54)
Side Angle 26_ PRO-R Preload 1.0 (2.54)
Rear Track Shock
(RTS)
Chaincase Base Fox HPG w/IFP
Center Distance (inches) 7.53 Adventure/PRO-R Walker Evans Needle
Top Gear (Stock) 23 w/Remote Reservoir
Bottom Gear (Stock) 39 16 Click Compression Adjustable
Chain (Stock) 72 Factory Setting** = 4
Rider Weight*
Reverse System PERC
120 - 260lbs.
Electrical
Alternator Output Rider Weight*
Operating Voltage 13.5 - 14.5 VDC 90 - 150lbs.
Watts @ 13.5 VDC (Total) 400 Rate lbs/in (N/mm) 120 (21)
18_ @1700 RPM HD RTS Spring PN: 7043585-385
Ignition Timing
Coolant Temp = 120_F (49_C) Rider Weight*
Spark Plug Gap in.(mm) .027 (.70) 240 - 335+lbs.
Spark Plug NGK BPR9ES
Spring length set to rider weight
Front Suspension
Suspension Type PRO-RIDE (Fixed Camber) RTS Spring
STD gauge supplied with vehicle.
Shocks Rider / Weight Setting
LW and HD springs - Use tape
BASE/Adventure Fox HPG w/IFP measure and RTS Spring Guide
PRO-R Walker Evans Needle Piggyback Table located in the Steering/
16 Click Compression Adjustable Suspension Chapter.
Rear Travel
IFS Spring Rate 14 (35.6)
100 (17.5) Inches (cm)
lbs/in (N/mm)
Preload - Inches (cm) NOTE: * = Rider weight in everyday clothing.
Base/Adventure 3.25 (8.25) ** = From full soft (CCW) position.
PRO-R 2.875 (7.3)
Ski Center Distance
Inches (cm) 42.5 (108)
Camber Inches (cm) NOT ADJUSTABLE
Toe Out - Inches (mm) 0 -1/8 (0 - 3)

1.23
General Information
2012 800 Switchback Clutch Settings
800 Switchback (feet) Weight Spring Spring Helix
Gearing
S12BR8GSA / S12BR8GSL
0-600
10-66
(0-2000)
800 Switchback PRO-R 600-1200
BLU/BLK
10-64 123-203
S12BS8GSA / S12BS8GSB / S12BS8GSC / S12BS8GSL (2000-4000) BLACK
7043064
120-310 22:36-70
S12BS8GEL / S12BS8GSM / S12BS8GSP 1200-1800
10-62 7043681
(4000-6000) 64/42 - .36
1800-2400 5135401
800 Switchback PRO-R Adventure INTL (6000-8000)
S12BC8GEL 10-60 BLK/PUR
2400-3000
BLACK 160-240
(8000-10,000)
7043363
Engine 140-330 20:38-70
3000-3600 7043342
10-56
(10,000-12,000)
Case Reed Induction
Model Number S4360-8044-OL8G
Piston to Cylinder
.004-.0055 / 0.103-0.141 General
Installed Ring Gap Width (in/cm) 48 / 121.9
.017-.025 / 0.450-0.650
(inches / mm) Length (in/cm) 108 / 274
Operating RPM +0-300 8250 Height (in/cm) 46 / 117
Idle RPM 200 1700 Estimated Dry Weight (lb/kg) 465 / 211
Engagement RPM 200 3800 Fuel (Gallons / Liters) 11 / 41.6
Exhaust Valve Spring Orange Oil (Quarts / Liters) 3.4 / 3.3
Thermostat Opening Cooling System
120 / 49 5 / 4.7
Temperature ( F/ C) Capacity(Qts/ L)
Fuel Delivery Brake Fluid DOT 4

Drive Belt
Type - Number of Fuel Part Number 3211115
DC-CFI - 2
Injectors Width (inches / cm) 1.460 / 3.7
Throttle Body Marking 1204094 Side Angle 26_
Throttle Body Bore 48mm Circumference (inches / cm) 46.77 / 118.8
TPS Voltage @ Idle
0.94 +/- 0.01 VDC Chaincase
(5 VDC +/- .01 Input)
Fuel Pressure - PSI (bar) 58-60 (4.0-4.1) Top Gear (Stock) 22
Fuel Octane (R+M/2) Bottom Gear (Stock) 36
10% Ethanol 24 Resistor <91 Octane Chain (Stock) 70
(Non-Oxygenated) Gear Lube Polaris Synthetic (80W)
OR Capacity (oz / ml) 9 / 266
87/89/91+ Reverse System PERC

General Information

Pitch 2.52 (FTS)
Plies 2 Base Fox HPG w/IFP
Adventure/PRO-R Walker Evans w/Remote
Lug Height - Inches (cm) Reservoir
Base/Adventure 1.25 (3.175) (Ripsaw) 16 Click Compression
PRO-R 1.352 (3.43) (Cobra) Adjustable
Track tension sag in/mm Factory Setting** = 2
with 10 lbs/4.54kg placed FTS Spring Rate
1/4 - 3/8 (6.3 - 9.6mm) 120 - 310 (21 - 54.25)
16 in/40cm ahead of rear lbs/in (N/mm)
idler shaft
Electrical Length-Inches (cm) 7.5 (19.05)
Base Preload 1.0 (2.54)
Alternator Output ADV./PRO-R 1.0 (2.54)
Operating Voltage Preload
13.5 - 14.5 VDC
Watts @ 13.5 VDC Rear Track Shock
400
(Total) (RTS)
18_ @1700 RPM Base Fox HPG w/IFP
Ignition Timing Coolant Temp = 120_F Adventure/PRO-R Walker Evans Needle
(49_C) w/Remote Reservoir
Spark Plug Gap 16 Click Compression
.027 (.70) Adjustable
in.(mm)
Spark Plug NGK GR9A-EG
Standard RTS
PN: 7043160-133
Front Suspension Spring
Rider Weight*
Suspension Type PRO-RIDE (Fixed Camber) 120 - 260lbs.
150 (26.25)
Rate lbs/in (N/mm)
Shocks
Fox HPG w/IFP LW RTS Spring PN: 7041575-385
Base
Walker Evans Needle Piggyback Rider Weight*
Adventure/PRO-R
16 Click Compression 90 - 150lbs.
Adjustable Rate lbs/in (N/mm) 120 (21)
Factory Setting** = 6 HD RTS Spring PN: 7043585-385
IFS Spring Rate Rider Weight*
100 (17.5)
lbs/in (N/mm) 240 - 335+lbs.
Preload - Inches Rate lbs/in. (N/mm) 260 (45.5)
(cm) Spring length set to rider weight
Base 3.25 (8.25) using adjustment gauge.
Adventure/PRO-R 2.875 (7.3) STD Gauge PN: 9923267
Travel-Inches (cm) 9 (22.9) RTS Spring
Rider / Weight STD gauge supplied with
Ski Center Distance Setting vehicle. LW and HD springs - Use
Inches (cm) 42.5 (108) tape measure and RTS Spring
Setup Width 41.52 (105) Guide Table located in the
Camber Inches (cm) NOT ADJUSTABLE Steering/Suspension Chapter.
Toe Out - Inches Rear Travel
0 -1/8 (0 - 3) 14 (35.6)
(mm) Inches (cm)


1.25
General Information
2012 Switchback Assault Switchback Assault 1.3 Clutch Settings
Switchback Assault 1.3 (feet) Weight Spring Spring Helix
Gearing
S12CW8GSA / S12CW8GSL
0-600
10-66
(0-2000)
Switchback Assault 2.0 600-1200
BLU/BLK
10-64 123-203 23:39 - 72
S12CL8GSB / S12CL8GSM / S12CL8GEL (2000-4000) BLACK
7043064
120-310
1200-1800 7043681
10-62
Engine (4000-6000) 64/42 - .36
1800-2400 5135401
21:40 - 72
Liberty Liquid-Cooled / (6000-8000)
Engine Type 10-60 BLK/PUR
160-240
(8000-10,000) BLACK
7043363
Model Number S4361-8044-OL8G 140 - 330 20:42 - 72
3000-3600 7043342
10-58
Displacement / # Cylinders 794cc / 2 (10,000-12,000)

Stroke (inches/mm) 2.75 / 70
Piston to Cylinder Switchback Assault 2.0 Clutch Settings
.004-.0055 / 0.103-0.141
Clearance (inches/mm) DRIVE CLUTCH DRIVEN CLUTCH
ALTITUDE
Installed Ring Gap meters Shift Clutch Clutch Driven
.017-.025 / 0.450-0.650 (feet) Weight Spring Spring Helix
Gearing
(inches / mm)
0-600
Operating RPM +0-300 8250 (0-2000)
10-66
BLU/BLK
Idle RPM 200 1700 600-1200
10-64 123-203
(2000-4000) BLACK
7043064
Engagement RPM 200 3800 1200-1800
120-310
10-62 7043681
(4000-6000)
Exhaust Valve Spring Orange 64/42 - .36
20:42 - 72
1800-2400 5135401
Thermostat Opening (6000-8000)
120 / 49 10-60
Temperature ( F/ C) 2400-3000
BLK/PUR
BLACK 160-240
(8000-10,000)
140 - 330 7043363
Fuel Delivery 3000-3600
10-58 7043342
(10,000-12,000)
Type - Number of Fuel Drive Clutch Bolt Torque: 80 lb.ft. (108Nm)
DC-CFI - 2
Injectors Re-torque after running engine.
Throttle Body Marking 1204094
Throttle Body Bore 48mm WEIGHTS WHEN OPERATING IN PROLONGED
TPS Voltage @ Idle WARM TEMPERATURES (LATE FALL/SPRING
0.94 +/- 0.01 VDC
(5 VDC +/- .01 Input) SEASON) TO MAINTAIN PEAK OPERATING RPM.
Track
Fuel Octane (R+M/2)
10% Ethanol 24 Resistor <91 Octane Width - Inches (cm) 15 (38)
(Non-Oxygenated) Length - Inches (cm) 144 (365.76)
OR
Pitch 2.52
87/89/91+
Plies 2
Lug Height - Inches (cm)
Premium/Non-Ethanol 91+ 1.3 1.352 (3.43) (Cobra)
160 Resistor (Non-Oxygenated) 2.0 2.0 (5.08) (Series 4)
3/8 - 1/2 (1 - 1.3cm)
idler shaft

General Information
General Front Suspension
Width (in/cm) 48 / 121.9 Suspension Type PRO-RIDE (Fixed Camber) 1

Length (in/cm) 126 / 320 Walker Evans Needle Piggyback
Height (in/cm) 48 / 121.9 16 Click Compression
Shocks
Adjustable
Estimated Dry Weight (lb/kg) 457 / 212.7 Factory Setting** = 6
Fuel (Gallons / Liters) 11.5 / 43.5 IFS Spring Rate
100 (17.5)
Oil (Quarts / Liters) 3.4 / 3.3 lbs/in (N/mm)
Cooling System IFS Spring Installed
6.0/5.7 10.0 (25.4)
Capacity(Qts/ L) Length - Inches (cm)
Brake Fluid DOT 4 Front Vertical Travel
9 (22.9)
Drive Belt Inches (cm)
Part Number 3211115 Ski Center Distance
Width (inches / cm) 1.460 / 3.7 Inches (cm) 42.5 (108)
Side Angle 26_ Setup Width 41.52 (105)
Circumference (inches / cm) 46.77 / 118.8 Camber Inches (cm) NOT ADJUSTABLE
Toe Out - Inches
Chaincase 0 -1/8 (0 - 3)
(mm)
Top Gear (Stock) 23 Rear Suspension
Bottom Gear (Stock) 39
Chain (Stock) 72 Suspension Type Switchback 144 Tipped
Gear Lube Polaris Synthetic (80W) Walker Evans Piggyback
Capacity (oz / ml) 9 / 266 Front Track Shock 16 Click Compression
Reverse System PERC (FTS) Adjustable
Electrical
FTS Spring Rate
170 (21 - 54.25)
Alternator Output lbs/in (N/mm)
Operating Voltage FTS Spring Installed
13.5 - 14.5 VDC
Watts @ 13.5 VDC Length 7.25 (18.4)
400
(Total) Inches (cm)
18_ @1700 RPM Walker Evans
Ignition Timing Coolant Temp = 120_F w/Remote Reservoir
(49_C) Rear Track Shock
(RTS)
Spark Plug Gap Adjustable
.027 (.70)
in.(mm) Factory Setting** = 8
Spark Plug NGK GR9A-EG .359/77
Torsion Springs LH=7041629-329
RH=7041630-329
Rear Travel
14.5 (36.8)
Inches (cm)

1.27
General Information
S12CK6GSA / S12CK6GSL / S12CK6GEA (feet) Weight Spring Spring Helix
Gearing
0-600
Engine (0-2000)
10-64

10-62
Engine Type (2000-4000)
Case Reed Induction
1200-1800 BLACK/
10-60 BLK/PUR
Model Number S4316-6044-OL6G (4000-6000) GREEN
160-240
56/42 - .36
20:42 - 72
1800-2400 120 - 340 5135403
(6000-8000) 7042083
Bore (inches/mm) 3.04 / 77.25 2400-3000

10-56
(8000-10,000)
3000-3600
10-54
.0033-.0054 / 0.085-0.137
Installed Ring Gap
.017-.025 / 0.450-0.650
(inches / mm)
Exhaust Valve Spring Purple General
Thermostat Opening Width (in/cm) 46.5 / 118.1
120 / 49
Temperature ( F/ C)
Length (in/cm) 129 / 327.7

DC-CFI - 2
6.0/5.7
0.95 +/- 0.01 VDC
Chain (Stock) 72
Reverse System PERC

General Information
Width - Inches (cm) 15 (38) Suspension Type RMK144 Tipped 1

RydeFX Twin Tube
Pitch 2.52 (FTS)
170 (21 - 54.25)
Lug Height - Inches (cm) 2.0 (6.1) Series 4 lbs/in (N/mm)

3/8 - 1/2 (1.0 - 1.3cm) Inches (cm)
RydeAFX Twin Tube
(RTS)
Electrical .359/77
Alternator Output Torsion Springs LH=7041629-329
Operating Voltage RH=7041630-329
13.5 - 14.5 VDC
Watts @ 13.5 VDC Rear Travel
400 13 (33)
(Total) Inches (cm)
18_ @1700 RPM
Ignition Timing Coolant Temp = 120_F
(49_C)
Spark Plug Gap
.027 (.70)
in.(mm)
Front Suspension
Suspension Type PRO-RIDE RMK Adjustable

Shocks RydeFX Twin Tube
IFS Spring Rate
100 (17.5)
lbs/in (N/mm)
IFS Spring Installed
10.5 (26.7)
9 (22.9)
Inches (cm)
Ski Center Distance
Inches (cm) 39-40-41 (99.1-101.6-104.1)
Camber Inches (cm) 1.95 0.31 (4.3 .8)
Toe Out - Inches
0 -1/8 (0 - 3)
(mm)

1.29
General Information
S12CM6GSA / S12CM6GSL (feet) Weight Spring Spring Helix
Gearing
0-600
Engine (0-2000)
10-64

10-62
Case Reed Induction
1200-1800 BLACK/
10-60 BLK/PUR
160-240
56/42 - .36
20:42 - 72
1800-2400 120 - 340 5135403
(6000-8000) 7042083
Bore (inches/mm) 3.04 / 77.25 2400-3000

10-56
(8000-10,000)
3000-3600
10-54
.0033-.0054 / 0.085-0.137
Installed Ring Gap
.017-.025 / 0.450-0.650
(inches / mm)
120 / 49
Temperature ( F/ C)
Length (in/cm) 129 / 327.7

DC-CFI - 2
6.3/6.0
0.95 +/- 0.01 VDC
Chain (Stock) 72
Reverse System PERC

General Information

RydeFX Twin Tube
Pitch 2.86 (FTS)
150 (26.25)

RydeAFX Twin Tube
3/8 - 1/2 (1.0 - 1.3cm)
Rider Weight*
Alternator Output <160lbs./72kg 10-3/4" (27.3)
Operating Voltage 160-220lbs./72-99kg
13.5 - 14.5 VDC 10-1/4" (26)
Watts @ 13.5 VDC 220-280lbs./99-127kg
400 10-1/8" (25.7)
(Total) 280-340lbs./127-154kg 9-3/4" (24.8)
18_ @1700 RPM CAUTION: Do not adjust STD
Ignition Timing Coolant Temp = 120_F spring length greater than
(49_C) 10-3/4" or less than 9-5/8".
Spark Plug Gap HD RTS Spring PN: 7043741-067
.027 (.70)
in.(mm) Rate lbs/in. (N/mm) 250 (43.75)
Spark Plug NGK GR9A-EG Installed Length In. (cm)
(Track off ground)
Front Suspension Rider Weight*
250-300lbs./113-136kg 10-1/8" (25.7)
Suspension Type PRO-RIDE RMK Adjustable 300-350lbs./136-159kg 10" (25.4)
Shocks RydeFX Twin Tube CAUTION: Do not adjust HD
IFS Spring Rate 10-7/8" or less than 9-7/8".
100 (17.5)
lbs/in (N/mm)
Rear Travel
IFS Spring Installed 16 (40.6)
10.5 (26.7) Inches (cm)
Front Vertical Travel NOTE: * = Rider weight with gear.
9 (22.9)
Inches (cm)
Ski Center Distance
Inches (cm) 39-40-41 (99.1-101.6-104.1)
Camber Inches (cm) 1.95 0.31 (4.3 .8)
Toe Out - Inches
0 -1/8 (0 - 3)
(mm)

1.31
General Information
2012 600 PRO RMK 155 Clutch Settings
S12CG6GSA / S12CG6GSL / S12CG6GEA (feet) Weight Spring Spring Helix
Gearing
0-600
Engine (0-2000)
10-64

10-62
Case Reed Induction
1200-1800 BLACK/
10-60 BLK/PUR
160-240
56/42 - .36
20:42 - 72
1800-2400 120 - 340 5135403
(6000-8000) 7042083
Bore (inches/mm) 3.04 / 77.25 2400-3000

10-56
(8000-10,000)
3000-3600
10-54
.0033-.0054 / 0.085-0.137
Installed Ring Gap
.017-.025 / 0.450-0.650
(inches / mm)
120 / 49
Temperature ( F/ C)
Length (in/cm) 129/327.7
Type - Number of Fuel Estimated Dry Weight (lb/kg) 431/195.5

DC-CFI - 2
5.3/5.0
0.95 +/- 0.01 VDC
Chain (Stock) 72
Reverse System PERC

General Information

Pitch 2.86 (FTS)
150 (26.25)

3/8 - 1/2 (1.0 - 1.3cm) Inches (cm)
(RTS)
Watts @ 13.5 VDC
400 Rider Weight*
(Total)
<160lbs./72kg 10-3/4" (27.3)
18_ @1700 RPM 160-220lbs./72-99kg 10-3/8" (26.3)
(49_C) 280-340lbs./127-154kg 9-3/4" (24.8)
.027 (.70)
11.0" or less than 9-3/4".
Suspension Type PRO-RIDE RMK Adjustable (Track off ground)
Shocks Walker Evans HPG w/IFP Rider Weight*
100 (17.4) 300-350lbs./136-159kg 10" (25.4)
lbs/in (N/mm)
IFS Spring Installed spring length greater than
10.25 (26)
Length - Inches (cm) 10-7/8" or less than 9-7/8".
Front Vertical Travel Rear Travel
9 (22.9) 16 (40.6)
Ski Center Distance
Camber Inches (cm) 1.95 0.31 (4.3 .8)
Toe Out - Inches
0 -1/8 (0 - 3)
(mm)

1.33
General Information
S12CM8GSA / S12CN8GSL / S12CM8GEA (feet) Weight Spring Spring Helix
Gearing
0-600
Engine (0-2000)
10-68

10-66
1200-1800 7043063
10-64 BLACK
Model Number S4361-8044-OL8G (4000-6000)
140 - 330
56/42 - .36
20:42 - 72
1800-2400 5135403
(6000-8000)
Bore (inches/mm) 3.34 / 85 2400-3000
10-60
(8000-10,000) BLK/PUR
Stroke (inches/mm) 2.75 / 70 160-240
3000-3600 7043363
10-58
.0040-.0055 / 0.103-0.141
Installed Ring Gap
.017-.025 / 0.450-0.650
(inches / mm)
120 / 49
Temperature ( F/ C)
Length (in/cm) 129 / 327.7

DC-CFI - 2
6.3/6.0
0.94 +/- 0.01 VDC
Chain (Stock) 72
Reverse System PERC

General Information

RydeFX Twin Tube
Pitch 2.86 (FTS)
150 (26.25)

RydeAFX Twin Tube
3/8 - 1/2 (1.0 - 1.3cm)
Rider Weight*
Alternator Output <160lbs./72kg 10-3/4" (27.3)
Operating Voltage 160-220lbs./72-99kg
13.5 - 14.5 VDC 10-1/4" (26)
Watts @ 13.5 VDC 220-280lbs./99-127kg
400 10-1/8" (25.7)
(Total) 280-340lbs./127-154kg 9-3/4" (24.8)
18_ @1700 RPM CAUTION: Do not adjust STD
Ignition Timing Coolant Temp = 120_F spring length greater than
(49_C) 10-3/4" or less than 9-5/8".
Spark Plug Gap HD RTS Spring PN: 7043741-067
.027 (.70)
in.(mm) Rate lbs/in. (N/mm) 250 (43.75)
Spark Plug NGK GR9A-EG Installed Length In. (cm)
(Track off ground)
Front Suspension Rider Weight*
250-300lbs./113-136kg 10-1/8" (25.7)
Suspension Type PRO-RIDE RMK Adjustable 300-350lbs./136-159kg 10" (25.4)
Shocks RydeFX Twin Tube CAUTION: Do not adjust HD
IFS Spring Rate 10-7/8" or less than 9-7/8".
100 (17.5)
lbs/in (N/mm)
Rear Travel
IFS Spring Installed 16 (40.6)
10.5 (26.7) Inches (cm)
Front Vertical Travel NOTE: * = Rider weight with gear.
9 (22.9)
Inches (cm)
Ski Center Distance
Inches (cm) 39-40-41 (99.1-101.6-104.1)
Camber Inches (cm) 1.95 0.31 (4.3 .8)
Toe Out - Inches
0 -1/8 (0 - 3)
(mm)

1.35
General Information
2012 800 RMK Assault Clutch Settings
S12CN8GSA / S12CN8GEA / S12CN8GSB (feet) Weight Spring Spring Helix
Gearing
S12CN8GSL / S12CY8GSA
0-600
10-68
(0-2000)
Engine 600-1200
10-66 BLACK
(2000-4000)
Engine Type 1200-1800 7043063
Case Reed Induction (4000-6000)
10-64 BLACK
56/42 - .36
140 - 330 20:42 - 72
5135403
Model Number S4359-8044-OL8G 1800-2400
10-62 7043342
(6000-8000)
Displacement / # Cylinders 794cc / 2 2400-3000
10-60 BLK/PUR
(8000-10,000)
Bore (inches/mm) 3.34 / 85 160-240
3000-3600 7043363
Stroke (inches/mm) 2.75 / 70 10-58
(10,000-12,000)
Piston to Cylinder Drive Clutch Bolt Torque: 80 lb.ft. (108Nm)

.0040-.0055 / 0.105-0.141 Re-torque after running engine.
Installed Ring Gap
.017-.025 / 0.450-0.650 NOTE: OPTIONAL - USE 2 GRAM LIGHTER CLUTCH
(inches / mm)
Operating RPM +0-300 8250 WARM TEMPERATURES (LATE FALL/SPRING
Idle RPM 200 1700 SEASON) TO MAINTAIN PEAK OPERATING RPM.
Engagement RPM 200 3800 General
Width (in/cm) 48 / 121.9
Thermostat Opening
120 / 49 Length (in/cm) 129 / 327.7
Temperature ( F/ C)
Height (in/cm) 51 / 129.5
Fuel Delivery Estimated Dry Weight (lb/kg) 446 / 202.3
Type - Number of Fuel Fuel (Gallons / Liters) 11.5 / 43.5
DC-CFI - 2
Injectors Oil (Quarts / Liters) 3.4 / 3.3
Throttle Body Marking 1204094 Cooling System
5.3/5.0
Throttle Body Bore 48mm Capacity(Qts/ L)
TPS Voltage @ Idle Brake Fluid DOT 4
0.94 +/- 0.01 VDC
(5 VDC +/- .01 Input) Drive Belt
Fuel Pressure - PSI (bar) 58-60 (4.0-4.1) Part Number 3211115
Fuel Octane (R+M/2) Width (inches / cm) 1.460 / 3.7
10% Ethanol 24 Resistor <91 Octane Side Angle 26_
(Non-Oxygenated) Circumference (inches / cm) 46.77 / 118.8
OR Center Distance (inches / cm) 11.5 / 29.2
87/89/91+ Chaincase
(Up to10% Oxygenated) Center Distance (inches) 7.53
Top Gear (Stock) 20
Premium/Non-Ethanol 91+ Bottom Gear (Stock) 42
160 Resistor (Non-Oxygenated) Chain (Stock) 72
Reverse System PERC

General Information

Pitch 2.86 (FTS)
180 (31.5)
Lug Height - Inches (cm) lbs/in (N/mm)
Base 2.125 (5.4) (Competition) FTS Spring Installed
8.50 (21.6)
Powder 2.4 (6.1) Series 5.1 Length-Inches (cm)
Track tension sag in/cm Walker Evans Needle
with 10 lbs/4.54kg placed Piggyback
3/8 - 1/2 (1.0 - 1.3cm) Rear Track Shock
16 in/40cm ahead of rear 16 Click Compression
(RTS)
idler shaft Adjustable
Watts @ 13.5 VDC
400 Rider Weight*
(Total)
<160lbs./72kg 10-7/8" (27.6)
18_ @1700 RPM 160-220lbs./72-99kg 10-1/4" (26)
Ignition Timing Coolant Temp = 120_F 220-280lbs./99-127kg 10" (25.4)
(49_C) 280-340lbs./127-154kg 9-1/2" (24.1)
.027 (.70)
11.0" or less than 9-3/8".
PRO-RIDE RMK Wide (Track off ground)
Suspension Type
Adjustable Rider Weight*
Walker Evans Needle Piggyback 250-300lbs./113-136kg 10-1/8" (25.7)
16 Click Compression 300-350lbs./136-159kg 10" (25.4)
Shocks
Adjustable CAUTION: Do not adjust HD
Factory Setting** = 6 spring length greater than
10-7/8" or less than 9-7/8".
IFS Spring Rate
130 (22.75)
lbs/in (N/mm) Rear Travel
16 (40.6)
IFS Spring Installed Inches (cm)
10.75 (27.3)
NOTE: * = Rider weight with gear.
9 (22.9)
Inches (cm)
Ski Center Distance
Inches (cm) 41.5-42.5-43.5
(105.4-108-110.5)

Camber Inches (cm) 2.25 0.31 (5.7 .8)
Toe Out - Inches
0 -1/8 (0 - 3)
(mm)

1.37
General Information
2012 800 PRO RMK 155/163 Clutch Settings
800 PRO RMK 155 (feet) Weight Spring Spring Helix
Gearing
S12CG8GSA / S12CG8GEA / S12CG8GSB
0-600
S12CG8GSC / S12CG8GSL / S12CG8GSM (0-2000)
10-68
S12CG8GSP 600-1200
10-66 BLACK
(2000-4000)
155-222
800 PRO RMK 163 1200-1800
10-64 7043063
(4000-6000) BLACK
S12CH8GSA / S12CH8GEA / S12CH8GSB 140 - 330
56/42 - .36
20:42 - 72
1800-2400 5135403
S12CH8GSC / S12CH8GSL / S12CH8GSM (6000-8000)
10-62 7043342
S12CH8GSP
2400-3000
10-60 BLK/PUR
(8000-10,000)
Engine 160-240
3000-3600 7043363
10-58
(10,000-12,000)
Case Reed Induction
Model Number S4359-8044-OL8G
Piston to Cylinder
.004-.0055 / 0.103-0.141 General
Installed Ring Gap Width (in/cm) 46.5 / 118.1
.017-.025 / 0.450-0.650
(inches / mm) 155 = 129/327.7
Length (in/cm)
Operating RPM +0-300 8250 163 = 134/340.4
Idle RPM 200 1700 Height (in/cm) 51 / 129.5
Engagement RPM 200 3800 155 = 431/195.5
Estimated Dry Weight (lb/kg)
Exhaust Valve Spring Orange 163 = 437/198.7
Thermostat Opening Fuel (Gallons / Liters) 11.5 / 43.5

120 / 49
Temperature ( F/ C) Oil (Quarts / Liters) 3.4 / 3.3
Cooling System 155=5.3/5.0
Fuel Delivery Capacity(Qts/ L) 163=5.5/5.2
Type - Number of Fuel Brake Fluid DOT 4
DC-CFI - 2
Injectors Drive Belt
Throttle Body Marking 1204094 Part Number 3211115
Throttle Body Bore 48mm Width (inches / cm) 1.460 / 3.7
Side Angle 26_
TPS Voltage @ Idle Circumference (inches / cm) 46.77 / 118.8
0.94 +/- 0.01 VDC
(5 VDC +/- .01 Input) Center Distance (inches / cm) 11.5 / 29.2
Fuel Pressure - PSI (bar) 58-60 (4.0-4.1) Chaincase
Fuel Octane (R+M/2) Center Distance (inches) 7.53
10% Ethanol 24 Resistor <91 Octane Top Gear (Stock) 20
(Non-Oxygenated) Bottom Gear (Stock) 42
OR Chain (Stock) 72
87/89/91+ Gear Lube Polaris Synthetic (80W)
(Up to10% Oxygenated) Capacity (oz / ml) 9 / 266
Reverse System PERC

General Information
Width - Inches (cm) 15 (38) Suspension Type RMK Coil-Over 155/163 1

155 (393.7) Front Track Shock
Length - Inches (cm) Walker Evans HPG w/IFP
163 (414) (FTS)
Pitch 2.86 FTS Spring Rate
150 (26.25)
Plies 1 lbs/in (N/mm)
Lug Height - Inches (cm) 2.4 (6.1) Series 5.1 FTS Spring Installed
Track tension sag in/cm Length 8.50 (21.6)
with 10 lbs/4.54kg placed Inches (cm)
3/8 - 1/2 (1.0 - 1.3cm)
16 in/40cm ahead of rear Rear Track Shock
idler shaft (RTS)
Electrical Rate lbs/in (N/mm) 210 (36.75)
Alternator Output Installed Length In. (cm)
Operating Voltage (Track off ground)
13.5 - 14.5 VDC Rider Weight*
Watts @ 13.5 VDC
400 <160lbs./72kg 10-3/4" (27.3)
(Total)
160-220lbs./72-99kg 10-3/8" (26.3)
18_ @1700 RPM 220-280lbs./99-127kg 10-1/8" (25.7)
(49_C) CAUTION: Do not adjust STD
Spark Plug Gap spring length greater than
.027 (.70) 11.0" or less than 9-3/4".
in.(mm)
Spark Plug NGK GR9A-EG HD RTS Spring PN: 7043740-067
Rate lbs/in. (N/mm) 250 (43.75)
Front Suspension Installed Length In. (cm)
(Track off ground)
Suspension Type PRO-RIDE RMK Adjustable Rider Weight*
Shocks Walker Evans HPG w/IFP 250-300lbs./113-136kg 10-1/8" (25.7)
IFS Spring Rate 300-350lbs./136-159kg 10" (25.4)
100 (17.4) CAUTION: Do not adjust HD
lbs/in (N/mm)
IFS Spring Installed 10-7/8" or less than 9-7/8".
10.25 (26)
Rear Travel
Front Vertical Travel 16 (40.6)
9 (22.9) Inches (cm)
Inches (cm)
Ski Center Distance NOTE: * = Rider weight with gear.
Inches (cm) 39-40-41 (99.1-101.6-104.1)
Camber Inches (cm) 1.95 0.31 (4.3 .8)
Toe Out - Inches
0 -1/8 (0 - 3)
(mm)

1.39
General Information
SNOWMOBILE NUMBER
DESIGNATIONS
Model Number Designation
Example: S10BF6KSA
MODEL VIN OPTION

GROUP MODEL LINE MODEL TYPE ENGINE MODIFIER
YEAR IDENTIFIER IDENTIFIER
1st digit 2/3rd digit 4th digit* 5th digit* 6th/7th digits* 8th digit 9th digit**
A = Base Adventure
C = PRO-R Adv.
F = 120/121
D= LX
E= PRO-R LX
F = Rush Base A = Base
G = 155 Premium B = 1st Opt.
H = 163 Premium C = 2nd Opt.
6G = 600 DC-CFI-2
10 K = 144 Base L = Electric Start
B = Pro-Ride 6K = 600 DC-CFI-2+2 S = Standard
S 11 L = SB Assault 2 M = Electric
C = Hybrid 6N = 600 DC-CFI-4 E = Europe
12 M = 155 Base Start
8G = 794 DC-CFI-2
N = 155 Assault RMK P = Electric
P = Rush PRO-R Start
R = Switchback Base T = Track Opt.
S = Switchback
Premium
V = Limited Edition
W = SB Assault 1.35
Y = Assault 155 2.4
*=digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively
**=9th digit will be used on color/featured versions of models (not including the base)
First 3 digits and 9th digit are used in model number only. They are not used with the 17 digit VIN.
VEHICLE IDENTIFICATION NUMBER

VIN Number Designation
Vehicle Descriptors Vehicle Identifiers

Engine Modifier
Mfg. Location
Engine Size
Check Digit
World Mfg. ID
Model Year
Body Style
Individual Serial No.

Series
Type
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17
S N 1 B F 6 K S 0 2 2 0 0 0 0 0 0

General Information
Tunnel Decal machine model and V.I.N. number identification decal is
The Tunnel Decal has the Model Number (1), V.I.N.

located on the right front side of the tunnel. The V.I.N. (2)
number is permanently stamped into the tunnel. The
1
Number (2), and the Manufactured Date (3). These model number is embossed on the decal.
numbers should be referred to in any correspondence
regarding warranty, service or replacement parts. The
1 2 3
PUBLICATION PART NUMBERS

2010 Publications
MODEL OWNER'S MANUAL SUPPLEMENT PARTS BOOK

9922279
600 RUSH 9922276 9922280
9922648 (S10BF6KSL)
NOTE: Owners Manuals and electronic parts catalogs available at:

http://www.polarisindustries.com/en-us/RidersPortal.
2011 Publications
MODEL OWNER'S MANUAL SUPPLEMENT PARTS BOOK

9922839 (RUSH)
9922830 (RUSH LX) 9922831 (RUSH/LX)
600 RUSH
9922835 (PRO-R Retro LX) 9922836 (PRO-R)
9922841 (PRO-R)
9922829
9922840 (RUSH)
9922833 (Retro LX) 9922834 (RUSH/LX)
800 RUSH
9922837 (PRO-R Retro LX) 9922838 (PRO-R)
9922842 (PRO-R)
800 Switchback Assault 9922852 9922853
800 RMK 155 9922848 9922849
800 RMK Assault 9922844 9922850 9922851
9922845 (155)
800 PRO RMK 155/163 9922846
9922847 (163)


1.41
General Information
2012 Publications
OWNER'S
MODEL SUPPLEMENT PARTS BOOK
MANUAL
600 RUSH - 9923330 600 RUSH PRO-R - 9923327
600/800 RUSH 600 RUSH Electric Start - 9923326 800 RUSH PRO-R - 9923329
9923316
Models 800 RUSH Electric Start - 9923328 600 RUSH - 9923331
800 RUSH - 9923332 800 RUSH - 9923333
600 Switchback - 9923335
600 Switchback Electric Start - 9923309 600 Adventure - 9923310
600/800 800 Switchback - 9923336 800 Switchback - 9923337
9923308
Switchback Models 600 Switchback - 9923338 600 Switchback PRO-R - 9923339
800 Switchback Electric Start - 9923340 800 Switchback PRO-R - 9923341
800 Adventure INTL. - 9923483
800 Switchback 1.3 - 9923359 1.3 - 9923360
9923351
Assault 1.3/2.0 2.0 - 9923352 2.0 - 9923353
600 PRO RMK - 9923343
800 PRO RMK 155 - 9923346 600 RMK 144/155 - 9923350
800 PRO RMK 163 - 9923348 600 PRO RMK - 9923484
600/800 RMK
9923345 600 RMK 144 - 9923349 800 PRO RMK 155/163 - 9923347
Models
600 RMK 155 - 9923354 800 RMK 155 - 9923356
800 RMK 155 - 9923355 RMK Assault - 9923358
RMK Assault - 9923357

Service/Safety Bulletins
BULLETIN MODEL/YEAR DESCRIPTION

August Build 2010 600 RUSH PRO-RIDE Inspections/Updates
S-09-10 600 RUSH/2010
(Select Models)
S-10-01 600 RUSH/2010 2010 600 RUSH PRO-RIDE ECU Reflash (All Models)
800 PRO RMK 155/163
S-11-02 800 RMK Assault 2011 800 PRO RMK/RMK Assault Oil Hose Routing (All Models)
2011

General Information
GENERAL REFERENCE
Standard Bolt Torque Specification
1
Grade 2 Grade 5 Grade 8
Grade 2 Grade 5 Grade 8

Bolt Size
ft-lb (Nm) ft-lb (Nm) ft-lb (Nm)
1/4-20 5 (7) 8 (11) 12 (16)
1/4-28 6 (8) 10 (14) 14 (19)
5/16-18 11 (15) 17 (23) 25 (35)
5/16-24 12 (16) 19 (26) 29 (40)
3/8-16 20 (27) 30 (40) 45 (62)
3/8-24 23 (32) 35 (48) 50 (69)
7/16-14 30 (40) 50 (69) 70 (97)
7/16-20 35 (48) 55 (76) 80 (110)
1/2-13 50 (69) 75 (104) 110 (152)
1/2-20 55 (76) 90 (124) 120 (166)
Metric Bolt Torque Specification
GRADE
Bolt Size 4.6 4.8 8.8/8.9 10.9 12.9

FT-LB/NM (DRY THREADS)
M3 .3/.5 .5/.7 1/1.3 1.5/2 1.5/2

M4 .8/1.1 1/1.5 2/3 3/4.5 4/5
M5 1.5/2.5 2/3 4.5/6 6.5/9 7.5/10
M6 3/4 4/5.5 7.5/10 11/15 13/18
M8 7/9.5 10/13 18/25 26/35 33/45
M10 14/19 18/25 37/50 55/75 63/85
M12 26/35 33/45 63/85 97/130 110/150
M14 37/50 55/75 103/140 151/205 177/240
M16 59/80 85/115 159/215 232/315 273/370
M18 81/110 118/160 225/305 321/435 376/510

1.43
General Information
Gasoline Volatility Fuel / Oil Premix Ratios
MAXIMUM REID VAPOR AMBIENT AIR TEMP FUEL (GALLONS) 40:1 RATIO (OUNCES OF OIL)
CLASS PRESSURE LOW HIGH 5 16
110F+
A 7.0 psi (0.5 bar) 60F (16C) Formula:
(43C+)
110F 1 Gallon = 128 Ounces
B 9.0 psi (0.6 bar) 50F (10C) 128 / (Desired Ratio) = Ounces of oil for every 1
(43C)
gallon of fuel.
40F 128 / 40 (40:1 Ratio) = 3.2 ounces of oil for every 1
C 10.5psi (0.7 bar) 97F (36C)
(4C) gallon of fuel.
30F
D 12.0psi (0.8 bar) 85F (29C) Always mix ratio in 5 gallon increments.
(-1C)
20F
E 13.5psi (0.9 bar) 69F (21C) NOTE: A 40:1 premix should always be used during
(-7C)
engine break-in or after rebuilding the engine.
Add 2.45F for each 1000 ft (305m) above sea level
Fuel Recommendations
Gasoline is given a Reid Vapor Pressure (RVP) number
which reflects its ability to vaporize or mix with air at a For maximum performance, Polaris recommends the use
given temperature range. Gasoline vapor pressure is of 91 octane or higher non-oxygenated fuel. Although
measured by putting a sample of fuel inside a closed lower octane and/or oxygenated fuel is usable, some
container and applying a specified amount of heat to the engine performance will be lost and fuel economy will
container for a certain amount of time. RVP will vary from decrease.
about 7.0 PSI during the summer to approximately 13.5
PSI during the colder months. Service stations selling a Do not use lower than 87 octane fuel. Do not use
large volume of fuel will normally have the correct blend to oxygenated fuel containing more than 10% ethanol. Never
work well at all times throughout the year in their local use E85 fuel in your snowmobile.
area.
NOTE: Operating with an obstructed fuel system will
When the weather is very cold, gasoline must be able to result in serious engine damage. Perform
vaporize very quickly in order for an engine to start and maintenance as recommended.
warm up properly. If summer blend fuel is being used in the
winter, little or no vaporization will occur. Droplets will form Prolonged exposure to petroleum based products may
causing flooding and very hard starting. damage paint. Always protect painted surfaces when
handling fuel.
If winter blend fuel is being used during the summer
months, it may cause vapor lock (boiling fuel) inside the Fuel System Deicers
fuel lines, fuel pump, or carburetor. This will cause warm
If you use non-ethanol fuel (sometimes labeled non-
engine driveability problems and hard starting when
oxygenated), Polaris recommends the regular use of a
warm.
isopropyl-based fuel system deicer. Add one to two
ounces per gallon (8-16 ml per liter) of gasoline to prevent
damage resulting from fuel system icing. Never use
deicers or additives containing methanol. Polaris
recommends the use of Carbon Clean Plus.
If you use fuel with up to 10% ethanol (sometimes labeled

oxygenated) do not add deicers or additives that contain
any form of alcohol.

General Information
SAE Tap Drill Sizes Decimal Equivalents
Thread Size/ Drill Size Thread Size / Drill Size

1/64 ................................................................ ............. .0156
............. 1/32 ..................... ...............0312 .... 1 mm= .0394"
1
#0-80 3/64 1/2-13 27/64 3/64 ................................... ...............0469
#1-64 53 1/2-20 29/64 ............. 1/16 ..................... ...............0625
#1-72 53 9/16-12 31/64 5/64 ................................... ...............0781 .... 2 mm = .0787"
#2-56 51 9/16-18 33/64 ............. 3/32 ..................... ...............0938
7/64 ................................... ...............1094 .... 3 mm =.1181"
#2-64 50 5/8-11 17/32
............. 1/8......... .1250
#3-48 5/64 5/8-18 37/64 9/64 ................................... ...............1406
#3-56 45 3/4-10 21/32 ............. 5/32 ..................... ...............1563 .... 4 mm = .1575"
#4-40 43 3/4-16 11/16 11/64 ................................. ...............1719
#4-48 42 7/8-9 49/64 ............. 3/16 ..................... ...............1875 .... 5mm= .1969"
13/64 ................................. ...............2031
#5-40 38 7/8-14 13/16
............. 7/32 ..................... ...............2188
#5-44 37 1-8 7/8 15/64 ................................. ...............2344 .... 6 mm = .2362"
#6-32 36 1-12 59/64 ............. 1/4......... .25
#6-40 33 1 1/8-7 63/64 17/64 ................................. ...............2656 .... 7 mm = .2756"
#8-32 29 1 1/8-12 1 3/64 ............. 9/32 ..................... ...............2813
19/64 ................................. ...............2969
#8-36 29 1 1/4-7 1 7/64
............. 5/16 ..................... ...............3125 .... 8mm= .3150"
#10-24 24 1 1/4-12 1 11/64 21/64 ................................. ...............3281
#10-32 21 1 1/2-6 1 11/32 ............. 11/32 .................. ...............3438 .... 9 mm = .3543"
#12-24 17 1 1/2-12 1 27/64 23/64 ................................. ...............3594
#12-28 4.6mm 1 3/4-5 1 9/16 ............. 3/8......... .375
1/4-20 7 1 3/4-12 1 43/64 25/64 ................................. ...............3906 .... 10 mm = .3937"
............. 13/32 ................... ...............4063
1/4-28 3 2-4 1/2 1 25/32 27/64 ................................. ...............4219 .... 11 mm =.4331"
5/16-18 F 2-12 1 59/64 ............. 7/16...................... ...............4375
5/16-24 I 2 1/4-4 1/2 2 1/32 29/64 ................................. ...............4531
3/8-16 O 2 1/2-4 2 1/4 ............. 15/32 ................... ...............4688 .... 12 mm = .4724"
3/8-24 Q 2 3/4-4 2 1/2 31/64 ................................. ...............4844
............. 1/2......... .5 ....................... ............. 13mm = .5118"
7/16-14 U 3-4 2 3/4
33/64 ................................. ...............5156
7/16-20 25/64 ............. 17/32 ................... ...............5313
35/64 ................................. ...............5469 .... 14 mm = .5512"
Metric Tap Drill Sizes ............. 9/16 ..................... ...............5625
37/64 ................................. ...............5781 .... 15 mm = .5906"
Decimal Nearest ............. 19/32 ................... ...............5938
Tap Size Drill Size Equivalent Fraction 39/64 ................................. ...............6094
............. 5/8......... .625 ................... ............. 16mm=. 6299"
3x.50 #39 0.0995 3/32
41/64 ................................. ...............6406
3x.60 3/32 0.0937 3/32 ............. 21/32 ................... ...............6563 .... 17 mm =.6693"
4x.70 #30 0.1285 1/8 43/64 ................................. ...............6719
4x.75 1/8 0.125 1/8 ............. 11/16 ................... ...............6875
45/64 ................................. ...............7031 .... 18 mm = .7087"
5x.80 #19 0.166 11/64 ............. 23/32.................... ...............7188
5x.90 #20 0.161 5/32 47/64 ................................. ...............7344 .... 19 mm = .7480"
6x1.00 #9 0.196 13/64 ............. 3/4......... .75
49/64 ................................. ...............7656
7x1.00 16/64 0.234 15/64 ............. 25/32 ................... ...............7813 .... 20 mm = .7874"
8x1.00 J 0.277 9/32 51/64 ................................. ...............7969
8x1.25 17/64 0.265 17/64 ............. 13/16 ................... ...............8125 .... 21 mm =.8268"
53/64 ................................. ...............8281
9x1.00 5/16 0.3125 5/16
............. 27/32 ................... ...............8438
9x1.25 5/16 0.3125 5/16 55/64 ................................. ...............8594 .... 22 mm = .8661"
10x1.25 11/32 0.3437 11/32 ............. 7/8......... .875
10x1.50 R 0.339 11/32 57/64 ................................. ...............8906 .... 23 mm = .9055"
............. 29/32 ................... ...............9063
11x1.50 3/8 0.375 3/8 59/64 ................................. ...............9219
12x1.50 13/32 0.406 13/32 ............. 15/16.................... ...............9375 .... 24 mm = .9449"
12x1.75 13/32 0.406 13/32 61/64 ................................. ...............9531
............. 31/32 ................... ...............9688 .... 25 mm = .9843"
63/64 ................................. ...............9844
............. 1............ 1.0

1.45
General Information
Measurement Conversion Chart Piston Wash / Spark Plug Reading
Changing temperature, barometer, altitude, and fuel
UNIT OF supply are just a few of the factors that can affect the day
MULTIPLIED BY CONVERTS TO
MEASURE to day performance of your engine. That is why using
ft-lb x 12 = in-lb Exhaust Gas Temperatures (EGT) are important for
in-lb x.0833 = ft-lb maintaining optimum performance. There are two
ft-lb x 1.356 = N-m methods for helping you determine what the EGTs are for
your machine. Piston wash and the coloring of your spark
in-lb x.0115 = kg-m
plug. The piston wash is by far the most valuable tool in
N-m x.7376 = ft-lb concluding EGTs, with the spark plug color running a
kg-m x 7.233 = ft-lb distant second. Use the illustrations below to help
kg-m x 86.796 = in-lb establish the EGTs for your machine.
kg-m x 10 = N-m
in x 25.4 = mm
mm x.03937 = in
in x 2.54 = cm
mile x 1.6 = km
km x.6214 = mile
Ounces (oz) x 28.35 = grams (g)
grams (g) x.035 = Ounces (oz)
= Fluid Ounces
ccs x.03381
(oz)
lbs x.454 = kg
kg x 2.2046 = lbs
= Cubic
Cubic Inches x 16.387
Centermeters
Cubic Centimeters x.061 = Cubic Inches
Imperial pints x.568 = liters (l)
liters (l) x 1.76 = Imperial pints
Imperial quarts x 1.137 = liters (l)
liters (l) x.88 = Imperial quarts
Imperial quarts x 1.201 = US quarts
US quarts x.833 = Imperial quarts
US quarts x.946 = liters
liters x 1.057 = US quarts
US gallon x 3.785 = liter
liter x.264 = US gallon
Pounds force per = Kilo pascals
x 6.895
square inch (psi) (kPa)
= Pounds force per
Kilo pascals (kPa) x.145
square inch (psi)

General Information
Glossary Of Terms DET (Detonation Elimination Technology): Engine
ABDC: After bottom dead center.

monitoring and control software that reduces ignition
timing and/or adds fuel when detonation is detected.
1
ACV: Alternating current voltage. Dial Bore Gauge: A cylinder measuring instrument which
uses a dial indicator. Good for showing taper and out-of-
Alternator: Electrical generator producing voltage round in the cylinder bore.
alternating current.
Electrical Open: Open circuit. An electrical circuit which
ATDC: After top dead center. isn't complete.
BBDC: Before bottom dead center. Electrical Short: Short circuit. An electrical circuit which
is completed before the current reaches the intended load.
BDC: Bottom dead center.
(i.e. a bare wire touching the chassis).
BTDC: Before top dead center.
End Seals: Rubber seals at each end of the crankshaft.
CC: Cubic centimeters.
Engagement RPM: Engine RPM at which the drive clutch
Center Distance: Distance between center of crankshaft engages to make contact with the drive belt.
and center of driven clutch shaft.
ft.: Foot or feet.
CFI: Cleanfire Fuel Injection fuel management and ignition
ft-lb: (foot-pound) A force of one pound at the end of a
system. In this system, all system and chassis voltage is
lever one foot in length, applied in a rotational direction.
DC.
g: Gram. Unit of weight in the metric system.
Chain Pitch: Distance between chain link pins (No. 35 =
3/8" or 1 cm). Polaris measures chain length in number of gal.: Gallon.
pitches.
ID: Inside diameter.
CI: Cubic inches.
in.: Inch/inches.
Clutch Buttons: Plastic bushings which aid rotation of the
movable sheave in the drive and driven clutch. in-lb: (inch pounds) A force of one pound at the end of a
lever one foot in length, applied in a rotational direction. 12
Clutch Offset: Drive and driven clutches are offset so that in. lbs. = 1 ft. lb.
drive belt will stay nearly straight as it moves along the
clutch face. kg/cm2: Kilograms per square centimeter.
Clutch Weights: Three levers in the drive clutch which kg-m: Kilogram meters.
relative to their weight, profile and engine RPM cause the
drive clutch to close and grip the drive belt. Kilogram/meter: A force of one kilogram at the end of a
lever one meter in length, applied in a rotational direction.
Crankshaft Run-Out: Run-out or bend of crankshaft
measured with a dial indicator while crankshaft is l or ltr: Liter.
supported between centers on V blocks or resting in
crankcase. Measure at various points especially at PTO. lbs/in2: Pounds per square inch.
CVT: Continuously Variable Transmission (Drive Clutch Left or Right Side: Always referred to based on normal
System) operating position of the driver.
DCV: Direct current voltage. m: Meter/meters.
DC-CFI: Cleanfire Fuel Injection fuel managment and
Mag: Magneto.
ignition system featuring a stator with a separate DCV
system coil and ACV lighting coil.

1.47
General Information
Magnetic Induction: As a conductor (coil) is moved Volt: The unit of measure for electrical pressure of
through a magnetic field, a voltage will be generated in the electromotive force. Measured by a voltmeter in parallel
windings. Mechanical energy is converted to electrical with the circuit.
energy in the stator.
Watt: Unit of electrical power. Watts = amperes x volts.
mi.: Mile/miles.
WOT: Wide open throttle.
mm: Millimeter. Unit of length in the metric system. 1 mm
= approximately .040".
Nm: Newton meters.
OD: Outside diameter.
Ohm: The unit of electrical resistance opposing current

flow.
oz.: Ounce/ounces.
PERC: Polaris Electronic Reverse Control
Piston Clearance: Total distance between piston and

cylinder wall.
psi.: Pounds per square inch.
PTO: Power take off.
PVT: Polaris Variable Transmission
qt.: Quart/quarts.
Regulator: Voltage regulator. Regulates battery charging

system output at approx. 14.5 DCV as engine RPM
increases.
Reservoir (Surge) Tank: The fill tank in the liquid cooling

system.
Resistance: In the mechanical sense, friction or load. In

the electrical sense, ohms, resulting in energy conversion
to heat.
RPM: Revolutions per minute.
Seized Piston: Galling of the sides of a piston. Usually

there is a transfer of aluminum from the piston onto the
cylinder wall.
Stator Plate: The plate mounted under the flywheel

supporting the battery charging coils.
TDC: Top dead center. Piston's most outward travel from

crankshaft.
VES: Variable Exhaust System

Maintenance
CHAPTER 2
Maintenance
PERIODIC MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
2
PERIODIC MAINTENANCE SCHEDULE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.3
MAINTENANCE PRODUCTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
ENGINE OILS / LUBRICANTS / MISC. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.5
BREAK-IN PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
ENGINE BREAK-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
FUEL/OIL PREMIX RATIO . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
DRIVE BELT BREAK-IN PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
ENGINE MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
VARIABLE EXHAUST VALVE CLEANING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.6
SPARK PLUGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.8
SPARK PLUG CAPS/SPARK PLUG TERMINALS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
SPARK PLUG WIRE MAINTENANCE/ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.9
SURGE TANK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
RECOMMENDED COOLANT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
COOLING SYSTEM BLEEDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.10
ENGINE MOUNT BOLT RE-TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.11
OIL PUMP ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.12
OIL PUMP BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
OIL INJECTION HOSE PRIMING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.13
OIL TANK/CLUTCH COVER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.14
OIL FILTER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.15
OIL SUPPLY HOSE ROUTING/PANDUIT STRAP. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.16
PVT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
BELT DEFLECTION INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
TEAM/P2 DEFLECTION ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
TORQUE LIMITER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.17
CLUTCH ALIGNMENT/OFFSET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
OFFSET/FLOAT ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.18
ADJUSTING ENGINE MOUNT BOLTS/ENGINE ALIGNMENT . . . . . . . . . . . . . . . . . . . 2.19
FUEL/INTAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
FUEL FILTER - DC-CFI-4 MODELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
FUEL FILTER - DC-CFI-2 MODELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.20
FUEL HOSE INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.21
FUEL TANK VENT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
AIR BOX/PRE-FILTERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.22
AIR BOX SERVICING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.23
CHASSIS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
DOOR/HOOD REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.24
CHAIN CASE OIL LEVEL CHECK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
CHAIN CASE OIL REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
DRIVE CHAIN TENSION ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.26
CHAIN CASE FASTENER RE-TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
BRAKE SYSTEM MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
BRAKE LEVER TRAVEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
BRAKE FLUID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.27
BRAKE PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
THROTTLE CABLE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
THROTTLE LEVER FREE-PLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28
THROTTLE CABLE ROUTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.28

2.1
Maintenance
STEERING / SUSPENSION MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
HANDLEBARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
ADJUSTABLE RISER. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.29
SKI/SKI SKAG FASTENERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
TRACK TENSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.30
TRACK ALIGNMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.31
SUSPENSION PIVOTS/LUBRICATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
SUSPENSION LUBRICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.32
ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
HEADLIGHT BULB REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
TAIL LAMP REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.33
OFF-SEASON STORAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
CHASSIS AND HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
CLUTCH AND DRIVE SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
CONTROLS AND LINKAGE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
ELECTRICAL CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
CARBURETOR/THROTTLE BODY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
FUEL SYSTEM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
CORROSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
SHOCKS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34
BATTERY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2.34

Maintenance
PERIODIC MAINTENANCE
Periodic Maintenance Schedule
Periodic Maintenance Table
Frequency / Intervals 2
Item 150 mi. 500 mi. 1000 mi. 2000 mi. Pre-
(240 km) (800 km) (1600 km) (3200 km) Season
Drive / Driven Clutch
Clutch Alignment / Offset I I
Drive Belt Condition / Ride Out Pre-Ride Inspection I
Drive / Driven Clutch Condition I C I I C
Drive Belt Tension I I
Engine
Engine Mounts I I I I
Engine Mount Screws
2010-2011 Models with 14mm Head Diameter Bolts Re-torque engine mount screws every 1,000 miles (1,600 km).
2012/All with 16mm Head Diameter Bolts Inspect every 1,000 miles (1,600 km).
Recoil Handle / Rope / Function I I I I
Engine Torque Link I I I
Cylinder Head Bolts I I I I I
Cylinder Base Nuts I I I
Ignition Timing I I
Spark Plugs I I I R I
Exhaust System / Retaining Springs I I I I
VES Valves / Solenoid / Hoses I/C I/C I/C I/C
Cooling System / Hoses / Coolant Level / Heat
Pre-Ride Inspection I
Exchangers
Oil Filter I I
Brake System
Hose Condition / Routing I I I I
Fluid Level / Leaks / Fluid Condition I I I I
Brake Pads / Brake Disc I I I I
Parking Brake I I I I
Brake Fluid R
Fuel System
Idle RPM I I I I
Fuel Filter Replace every 2,000 miles (3,200km) or every 2 years.
Throttle Lever / Throttle Cable I L L L L

2.3
Maintenance
Periodic Maintenance Table
Frequency / Intervals
Item 150 mi. 500 mi. 1000 mi. 2000 mi. Pre-
(240 km) (800 km) (1600 km) (3200 km) Season
Fuel / Vent Hoses I I I I I
Oil Pump Adjustment I I
Oil Hoses I I I I I
Air Box I I I
Electrical System
Auxiliary Shut-Off Pre-Ride Inspection I
Throttle Safety Switch Pre-Ride Inspection I
Ignition Switch Pre-Ride Inspection I
Headlights / Brake light / Taillights Pre-Ride Inspection I
Hand / Thumbwarmers Pre-Ride Inspection I
PERC Reverse System Pre-Ride Inspection I
Chassis / Suspension
Ski Toe Alignment I I I
Suspension Mounting Bolts Pre-Ride Inspection I
Rear Chain Case Fasteners
2010-2011 Pro-Ride Models Re-torque three lower fasteners every 1,000 miles (1,600 km).
2012 (Bonded Chaincase) Visually Inspect
Steering Fasteners / Linkage / Handlebars Pre-Ride Inspection I
Driveshaft / Jackshaft Bearings L L L L
Ski Fasteners I I I I
Drive Chain Tension I I I I I
Chaincase / Gearcase Oil I I I R I
Track Alignment / Track Tension I I I I I
High performance shocks should have oil changed and
Rebuildable IFP Shocks
recharged at the end of every riding season.
Rail Slide Condition I I I I I
Bogie / Wheel Condition / Fastener Bolts I I I I I
Hood / Seat / Chassis / Engine Compartment C C
L = Lubricate / I = Inspect or Adjust / R = Replace / C = Clean

Maintenance
MAINTENANCE PRODUCTS DESCRIPTION PART NUMBER
Engine Oils / Lubricants / Misc. Fuel Stabilizer

Quart 2870652
2.5 Gallon 2872280
2
DESCRIPTION PART NUMBER
Three Bond Sealant 5oz. 2871557
Premium 2-Cycle Semi-Synthetic Oil
(Use for engine break-in.) Loctite 242 2871950
Quart 2875035 Shock Thread Spray Lubricant
Gallon 2875036 Use only on Rush rear track shocks
2.5 Gallon 2875038 2878018
without thrust bearing. Do not use
16 Gallon 2875037 lubricant on any other shock.
55 Gallon 2875039
330 Gallon 2875040
VES Gold Plus 2-Cycle Oil
(All Variable Exhaust Engines)
Quart 2877882
Gallon 2877883
2.5 Gallon 2877884
16 Gallon 2877885
55 Gallon 2877886
330 Gallon 2877892
Liter 2877887
4 Liter 2877888
25 Liter 2877889
208 Liter 2877890
Synthetic Chaincase Lubricant
Quart 2873105
Gallon 2873106
2.5 Gallon 2872952
Antifreeze 60/40 Premix
Quart 2871534
Gallon 2871323
55 Gallon 2872278
Shock Oil - 5W - Walker Evans 2874522
Shock Oil - 5W - Fox
Quart 2870995
Gallon 2872279
Shock Oil - 5W - Ryde FX / Arvin 2873716
Brake Fluid - DOT 4 2872189
Fogging Oil
Aerosol 2870791
Quart 2871517
Premium All Season Grease
3oz. Grease Gun Kit 2871312
14oz. Tube 2871423
Starter Grease 2871460
Carbon Clean Plus 2871326
Isopropyl 2870505

2.5
Maintenance
BREAK-IN PROCEDURES ENGINE MAINTENANCE
Engine Break-In Procedure Variable Exhaust Valve Cleaning
The first tank of fuel is considered the break-in period for The exhaust valve guillotines must be cleaned to ensure
the engine. During this time it is critical to not operate the maximum engine performance and throttle response.
engine at full throttle for more than a few seconds. Vary the
throttle speed as much as possible. Monitor engine FASTENERS
temperatures and fluid levels often during the break-in
period.
NOTE: During the engine break-in period, verify the

oil injection system is functioning by monitoring the GUILOTINE
EV ASSEMBLY
oil level in the oil tank. If the oil level does not drop,
GASKET
inspect the oil injection system.
Polaris recommends filling the oil tank and pre-mixing the

first full tank of fuel with Premium 2-Cycle Semi-Synthetic
Oil when the engine is either new or refurbished (new 1. Remove the vent hose from the EV base fitting.
pistons, crankshaft, cylinder, etc.). Polaris semi-synthetic
2. On the MAG VES assembly, remove the two
engine oil will seat the rings faster than when using Polaris
fasteners that secure the valve assembly to the
VES Gold Plus oil.
cylinder. Remove the cover after the assembly is
removed from the engine.
After the break-in period use Polaris VES Gold Plus
engine oil for normal operation. 3. On the PTO VES assembly, remove all four screws.
Remove the cover and spring from the EV base.
Fuel/Oil Premix Ratio 4. Remove the two screws that secure the lower steering
During the break-in period, premix the first tank a fuel (10 shaft clamp to the over structure. Doing this will
US gallons) using a 40:1 (fuel:oil) ratio. provide clearance to remove the EV valve assembly.
Formula = 1 US Gallon = 128oz. / 40 (Desired Ratio) =

3.2oz. for every 1 US gallon of fuel.
10 US gallons of fuel requires 32oz. of oil to achieve a 40:1

premix ratio.
Always mix fuel and oil 5 gallons at a time. Never fill the
tank with fuel and then add oil.
Drive Belt Break-In Procedure

The break-in period for a new drive belt is 30 miles. During
this time, vary the throttle position under 50% and limit full
throttle use.
New drive belts that feature a sanded finish should be first 5. Carefully extract the guillotine out of the cylinder.
washed with warm, soapy water and allowed to air dry Discard the gasket. Do not excessively push on the
prior to use. lower steering shaft when removing the EV assembly.
Always take time to warm up the belt and driveline prior to 6. Using a clean rag or shop towel, remove the oil
operating the snowmobile. Free track and skis from the residue from the cylinder, guillotine, and EV base.
ground before engaging throttle.

Maintenance
7. Inspection: 9. Inspect the VES gas ports on the cylinder(s) for
blockage. Remove the spark plugs and use a piston
Inspect the guillotine for signs of damage. Replace
inspection light to illuminate the port(s).
guillotine if damage is found. Inspect the cylinder
and piston for damage if guillotine is damaged.
Inspect the spring. Replace if rusted, damaged, or
bent. 2
Inspect bellows. Replace if damaged or
excessively worn. X
Submerse the assembly in parts cleaner.
Thoroughly flush the EV housing base, bellows,
and mating surfaces. Verify no carbon is in the gas
CLEAN GAS TRANSFER PORT
transfer ports.
10. Light must be seen through the VES gas port(s). If a

port appears to be blocked, use compressed air or a
long .075" drill bit to clean the port.
NOTE: Do not drill hole marked: X.
CAUTION
Rotate the crankshaft to move piston(s) to BDC-below

VES gas ports. Do not damage pistons when using drill
bit to clean ports.
CLEAN GAS TRANSFER PORTS 5mm
2mm
CYLINDER CUTAWAY
NOTE: The transfer port diameter starts at 5mm and

then tapers to 2mm as it approaches the cylinder wall.
Do not damage taper and/or 2mm bore with a larger
Clean the guillotine with brake cleaner and a piece
drill bit.
of fine steel wool. Clean only to remove hardened
carbon deposits.
11. Install a new gasket, then reinstall the EV assembly.
8. Once clean, rinse blade with mild detergent and Apply Loctite 242 to the fastener threads, and
water. Dry completely. torque to specification.

2.7
Maintenance
NOTE: Always install a new EV base gasket. Never re- Spark Plugs
use the gasket, or modify a new gasket.
Inspect/replace the spark plugs as outlined in the periodic
maintenance table.
=T
The spark plugs can be serviced by opening the left and
Exhaust Valve Housing Fasteners: right door panels.
10.5-13.5 ft-lb (14.3-18.3 Nm) - Apply Loctite 242
Replace a spark plug when the following occurs:
12. Reconnect the vent hoses.
Spark plug is damaged/insulator is cracked or
13. Torque lower steering post clamp fasteners to missing
specification. Plug electrode/insulator is fouled
Replace at interval in maintenance table
=T
When inspecting a spark plug, take note of the electrode
Lower Steering Post Clamp Fasteners: and insulator color. A light brown/dark tan color indicates
15 ft-lb (20 Nm) the engine is running properly.
If the spark plug electrode/insulator is white, the engine

NOTE: To obtain maximum exhaust valve may be running lean. Inspect the engine, throttle body
performance, Polaris recommends using Polaris VES boots, etc. for air leaks.
Gold Plus Synthetic Two-Stroke engine oil.
Never mix different brands of engine oil. If the spark plug electrode/insulator is black, oily, or shows
heavy soot, the engine may be running rich. Inspect the
engine, fuel system, and lubrication system for problems.
Set the electrode gap to specification before installing a

new spark plug.
= In. / mm.
Spark Plug Gap:.027 (.70mm)
=T
Spark Plug Torque:
18-21.6 ft-lb (24-30 Nm)
Apply anti-seize to threads.

Maintenance
Spark Plug Caps/Spark Plug Terminals Spark Plug Wire Maintenance/Routing
Inspect the spark plug caps when performing spark plug Inspect each spark plug wire and the routing of both high
maintenance. tension wires when performing spark plug maintenance.
Visually inspect the terminal ring inside the cap and the
spark plug tip for oblonging/uneven wear. Replace the
Replace damaged wires/ignition coils if found. Verify the
spark plug wires are routed as shown in the corresponding 2
spark plug and corresponding cap if the wear patterns on photo below. Proper spark plug wire routing is critical in
the cap terminal ring and spark plug terminal resemble the preventing spark plug cap/wire wear.
photos below.
Spark Plug Cap Terminal Ring Wear:

TERMINAL OBLONGED=REPLACE CAP/PLUG
A
A = Panduit strap securing both high tension wires to EV

vent hose.
B = T-Clip
Spark Plug Cap Terminal Wear:

WEAR ON/ABOVE INDENTATION=REPLACE
WEAR BELOW INDENTATION=GOOD
Use gentle force and a slight twisting motion when

installing plug caps. An audible click should be heard
when the terminal ring is properly seated below terminal
tip indentation.

2.9
Maintenance
Surge Tank 6. Apply the parking brake and start the engine.
7. Immediately add coolant to the surge tank if the
Keep the level of the coolant inside the surge tank at the
coolant level drops significantly after the engine is
FULL COLD level mark (A) when the coolant is at room
started. Watch the level and add more coolant until the
temperature.
level stops dropping.
Always add coolant when the cooling system is COLD.
NOTE: Squeeze the coolant hoses to purge air from
the cooling system.
8. Continue to run the engine until the engine

temperature is at least 130 F (54 C). Secure the
bleed screw after the thermostat begins to open and
coolant begins to flow out of the bleed screw.
A 9. Verify the tunnel coolers and front heat exchanger (if
equipped) begin to warm as the engine continues to
run.
10. The thermostat outlet bleed screw may need to be
opened slightly to allow any residual air trapped in the
outlet to escape.
11. Verify that all of the coolers are warm, including the
tunnel-length cooling system. Shut off the engine
once all of the tunnel coolers are warm. Release the
parking brake.
CAUTION
CAUTION Always verify all tunnel coolers / heat exchanger are

warm to the touch. A cooler or return hose that is
Never remove the surge tank pressure cap when the significantly colder than another cooler or hose is an
cooling system is warm. Severe burns to skin may occur indication of trapped air within the cooling system.
from escaping coolant or steam.
12. Allow time for the coolant temperature to cool. Re-
check the coolant level in the surge tank. Add more
Recommended Coolant coolant if required. Reinstall the surge tank cap, hood,
and engine compartment door panels.
Use Polaris Premium 60/40 pre-mixed antifreeze. This
premium antifreeze is rated for temperatures down to
-62F (-52C).
Cooling System Bleeding

1. Position the snowmobile in a well-ventilated area.
2. Raise the front-right ski/suspension off the ground.
3. Allow the cooling system to cool completely. Open the
engine compartment door panels. Remove the hood.
4. Verify the coolant level in the surge tank is at the
COLD mark. Fill the surge tank with coolant if
required. Loosely install the pressure cap.
5. Open the thermostat housing bleed screw. Wrap a
clean shop towel around the housing to absorb any
coolant that may flow out of the bleed screw.

Maintenance
Engine Mount Bolt Re-Torque MAG Engine Mount Bolts
NOTE: The engine mount bolt maintenance

procedure only applies to 2010-2011 Pro-Ride
vehicles using the original 14mm head diameter bolts.
2012 models and 2010-2011 engine mount bolt service 2

parts use 16mm head diameter bolts and only require
periodic visual inspection.
=T
Verify and re-torque the four engine mount bolts as 14mm Head Diameter Engine Mount Bolts:
outlined in the periodic maintenance table. Green M10x1.5x45-14mm Head (8.8)
30 ft-lb (41 Nm)
The drive clutch and exhaust silencer will require removal Silver M10x1.5x50-14mm Head (12.9)
to gain access to all four engine mount bolts. 35 ft-lb (48 Nm)
NOTE: Original 14mm head bolts on 2010 Pro-Ride Note two torque values for Bolts. Always clean engine
models were GREEN. Original 14mm head bolts on mount threads with compressed air or M10x1.5 tap
2011 Pro-Ride models were SILVER. Bolt color must before installing bolt(s). Apply Loctite Primer N and
be noted to properly torque fasteners. Loctite 242 when using original bolts.
PTO Engine Mount Bolts Detailed information regarding engine mount bolts can be
found in Chapter 3. See Engine Mount Bolt Service
Replacement Kit on page 3.20.

2.11
Maintenance
Oil Pump Adjustment 3. Access to the oil pump for inspection is between the
drive and driven clutches.
1. Verify the throttle cable free play is set to specification
(.010 - .030 ) and the throttle lever is synchronized to LOOK THROUGH THIS OPENING
the throttle plates.
LINKAGE ARM
SCRIBE MARK
LEVER NOTCH
OIL SUPPLY
4. Using a mirror and a flash light, visually inspect the

current oil pump setting. The scribe mark should be
aligned with the point of the lever notch when the
Oil Pump Adjustment Settings throttle plates are closed.
PART
NUMBER
ARM MARKING LEVER SETTING
CAUTION
2521000 600B
1204439 Linkage Adjustment
Set lever notch in-line with oil pump scribe
The oil pump lever and pump boss marks must be
1204363 800B mark. observed straight-on to yield accurate results.
1204438 Linkage Adjustment
5. If adjustment is required, locate the oil pump linkage
adjuster on the throttle body. Open and release the
CAUTION throttle several times to verify throttle plates are
closed.
Failure to properly set the oil pump lever arm may cause ADJUSTER SCREW
severe engine damage.
2. Remove the following components: JAM NUT
Left side compartment door panel
6. Loosen the adjuster jam nut. Using an Allen wrench,

turn the adjuster screw clockwise to raise the oil pump
lever arm. Turn the screw counter-clockwise to lower
the oil pump lever arm.
7. Visually inspect the lever notch/scribe mark
alignment. When in alignment, tighten the jam nut
without moving the adjuster screw.

Maintenance
NOTE: If the linkage arm comes off of the lever or Oil Injection Hose Priming
adjuster arm, verify the oil pump lever arm has not
rotated over-center prior to reinstalling the linkage.
CAUTION
Oil Pump Bleeding
FAILURE TO PROPERLY PRIME THE OIL PUMP
MAY CAUSE SEVERE ENGINE DAMAGE. 2
CAUTION
To prime the oil injection hoses follow these steps:
FAILURE TO PROPERLY BLEED THE OIL PUMP
MAY CAUSE SEVERE ENGINE DAMAGE. 1. Locate the oil pump linkage rod end on the top of the
throttle body.
2. Obtain a length of wire (coat hanger) with a small hook
on one end.
3. Hook the oil pump linkage rod on the throttle body as
shown in the photo.
4. With the engine compartment doors closed, have an
assistant start the engine. Pull the linkage upwards to
BLEED SCREW
set the oil pump to maximum flow. Continue doing this
for a few minutes.
5. Stop the engine. Inspect the oil injection hoses for air
bubbles. If there are air bubbles greater than one inch
in length, repeat step 4 until they are pushed out of the
hoses. Air bubbles less than one inch in length are
permissible, but you must verify they are moving
towards each oil injector when the engine is running.
The fact that the air bubbles are moving through the
1. The oil supply hose must be filled with oil to bleed the hoses indicates that the pump is properly bled.
pump.
2. Remove the following components:
Drive belt
Oil tank/clutch cover assembly PULL UP
Air box assembly
Throttle body assembly from the intake adapter
plate HANGER WIRE W/HOOK
3. Loosen the bleed screw (A). Verify a stream of oil
flows from the bleed screw.
4. After bleeding oil pump, secure bleed screw and wipe
up oil residue.
NOTE: Any time the engine is disassembled or

repaired, it is important to purge air within the oil
supply hose and oil pump.

2.13
Maintenance
Oil Tank/Clutch Cover Service 11. Installation is the reverse of removal. After installing
the supply hose on to the filter and installing the
The oil tank is mounted to the clutch cover assembly. The clamp, hold the oil tank high in the engine
oil tank/clutch cover assembly can be removed from the compartment with the supply hose pointed down to
vehicle to access components within the engine allow the trapped air to bleed upwards into the tank.
compartment.
NOTE: Because of the relative ease of removing both

CAUTION
the oil tank and clutch cover at the same time, both
processes have been combined although not all Verify the oil supply hose is not kinked after installing the
service procedures will require the removal of the oil tank/oil supply hose.
clutch cover.
12. Install the ECU bracket, and fill cap.
1. Open the engine compartment door panels, and 13. Torque the lower tank screw to specification. Install
remove the hood. the rubber strap.
2. Remove the hood assembly.
=T
FILL CAP/ECU
OIL LEVEL BRACKET
SENSOR
Oil Tank Mount Screw: 10 ft-lb (12 Nm)
FILL CAP/ECU BRACKET
MOUNT SCREW
RUBBER STRAP
3. Disengage the rubber strap from the cover at the back

of the oil tank.
4. Remove the screw securing the bottom of the tank to
the clutch cover.
5. Remove cap. Remove the ECU bracket from the oil
tank. Reinstall the fill cap. Disconnect the oil level
sensor.
6. Disconnect the two wire harness connectors from the
ECU.
7. Disconnect the wire harness connections at the
regulator/rectifier, and capacitor. Release the wire
conduits from the rosebud connectors.
8. Remove the four nuts securing the clutch cover from
the chassis.
9. Carefully pull up and release the cover from the
mounting studs.
10. Using a needle nose pliers, slide the clamp back and
remove the oil supply hose at the filter location. Use
the pliers to pinch the supply hose to prevent oil loss.

Maintenance
Oil Filter Service 5. Install oil tank/supply hose with clamp. Hold the tank
high in the engine compartment with the supply hose
The oil filter is located near the oil tank on 600 models, and pointed down to allow the trapped air to bleed
between the reed tracks on 800 models. The illustration upwards into the tank.
below shows the individual hose lengths depending on
model.
TANK-TO-FILTER HOSE
NOTE: Squeezing the hose with a pliers will push the
air out towards the tank. 2
600 = 6CM - CONVOLUTED TUBING = NONE
800 = 21CM - CONVOLUTED TUBING = 18CM
CAUTION
Severe engine damage will occur if the oil supply hose

is not properly bled of trapped air.
Verify the oil supply hose is not kinked after installing the
oil tank/oil supply hose.
OIL FILTER
6. Install the ECU bracket, and then fill cap.

7. Torque the lower tank screw to specification. Install
the rubber strap.
FILTER-TO-OIL PUMP HOSE
600 = 42CM - CONVOLUTED TUBING = 33CM
800 = 25CM - CONVOLUTED TUBING = 22CM =T
Oil Tank Mount Screw: 10 ft-lb (12 Nm)
600 Models:
800 Models:
1. Remove oil tank mounting screw and the rubber strap
securing the tank to the clutch cover. 1. Remove the drive belt and driven clutch assembly.
2. Slide the clamp off of the filter. Pinch off the oil supply 2. Remove oil tank mounting screw and the rubber strap
hose using a soft-jawed pliers. Remove the supply securing the tank to the clutch cover.
hose from the filter.
3. Remove the oil cap, and then slide the ECU bracket
3. Remove the oil filter from the oil pump oil supply hose. up and off of the oil tank. Reinstall the oil cap.
Have a clean shop rag available to wipe up any
residual oil. 4. Disconnect all of the ECU and assorted wiring
harnesses from the electrical center components.
4. Install a new filter with the arrow pointing in the
direction of flow (towards oil pump/away from tank). 5. Remove the clutch cover nuts, and then remove the
clutch cover from the vehicle.
FILLFILTER
OIL CAP/ECU BRACKET
NOTE: Position the oil tank on top of the drive clutch.

CLAMPS
Do not allow the oil tank to hang from the oil hose.
6. Remove the fuel supply and return hoses from the air
PINCH HERE box.
OIL FILTER
7. Reference Chapter 4 and remove the fuel hoses from
the fuel pump.
8. Remove the air box assembly.
9. Carefully disconnect the oil pump linkage arm from
the cam on the throttle body assembly. Note that the
oil pump lever will rotate over-center to the full open
600 LOCATION
position after it is disconnected, and will need to be
installed correctly during reinstallation.

2.15
Maintenance
10. Loosen the two throttle body gear clamps and remove 23. Reinstall the driven clutch and drive belt. Tighten drive
the throttle body from the adapter plate and secure it clutch fastener to 17ft-lb (23 Nm).
to the steering drag link.
11. Remove the throttle body adapter plate from the Oil Supply Hose Routing/Panduit Strap
crankcase. The reed cages can remain in the
To prevent disruptions in oil flow and premature oil hose
crankcase.
wear, verify the oil supply hose is free from kinks and/or
12. Position the oil tank so that air in the oil hose bleeds sharp bends.
up to the tank. Squeeze the hose with a pliers to force
the air upwards. Whenever servicing the oil supply hoses, oil pump, etc.
verify the hose(s) are not coming into the contact with
components that may prematurely wear the hose.
CAUTION
Some models feature a panduit strap to prevent the oil
Severe engine damage will occur if the oil supply hose hose from coming into contact with the front tunnel
is not properly bled of trapped air. bulkhead plate. While not on all models, the strap can be
installed on any vehicle.
13. Replace the oil filter making sure the arrow on the filter
points towards the oil pump.
IMPORTANT: All 800 models with front tunnel
14. If the reed cages were removed, clean each cage closeoff panels must have the panduit strap installed
assembly and reinstall. to prevent the oil hose from making contact with the
panel.
15. Reinstall the throttle body adapter plate. Install screws
and torque to 9 ft-lb (12 Nm) in a criss-cross pattern.
PANDUIT STRAP
OIL FILTER
16. Untie throttle body assembly that is secured to
steering drag link.
17. Locate the oil pump lever arm linkage. Pull up on the
linkage making sure the oil pump lever rotates
counter-clockwise.
18. Reconnect the oil pump lever linkage to the throttle
body.
NOTE: If the oil pump linkage is installed incorrectly,

the oil pump will be set to the full-rich setting.
PANDUIT
MAINTAIN
STRAP
SMOOTH CURVE
19. Reinstall the throttle body assembly into the adapter
plate boots. Tighten gear clamps. Prior to going to the
next step, verify the oil pump notch and index marks
are set properly. Secure the main oil supply hose to the PTO bearing oil
injector hose while maintaining a smooth curve in the hose
20. Reinstall the air box assembly and tighten gear
leading to the oil pump.
clamps.
NOTE: Air box divider plate may have to be removed

to ensure the air box boots are correctly installed on
to the throttle body.
21. Reinstall the clutch guard/oil tank/electrical center

assembly. Verify the oil supply hose is lying flat across
the intake track and not kinked. Reassemble all
electrical connections.
22. Reconnect the fuel supply/return hoses to the fuel
pump flange. Verify an audible click is heard when
installing the hoses.

Maintenance
PVT SYSTEM 4. The measurement should be 1-1/4" (3.2cm).
Belt Deflection Inspection

= In. / mm.
Excessive belt deflection is when the belt is too long or the
center distance is too short. The initial starting ratio will be
too high, resulting in performance loss. This is due to the
Belt Deflection: 1.25" (3.2cm) 2
belt rising too high in the drive clutch sheaves upon 5. If the measurement is not correct, adjust driven clutch.
engagement (A).
Team/P2 Deflection Adjustment
Insufficient belt deflection (B) is when the belt is too short
or the center distance is too long. The initial starting ratio
will be too low. In addition, the machine may creep when CAUTION
the engine idles, causing damage to the internal face of
the drive belt. The driven clutch can be damaged if the clutch is in
reverse drive.
1. Verify the drive system is in forward drive.

2. While holding the set screw with an Allen wrench,
loosen the jam nut.
3. Turn the set screw clockwise while holding the jam nut
stationary to increase the distance between the clutch
sheaves (increase belt deflection).
4. Turn the set screw counter-clockwise while holding
the jam nut stationary to decrease the distance
between the clutch sheaves (decrease belt
deflection).
5. Secure the jam nut while holding the set screw
stationary.
6. Raise the rear of the snowmobile using a track stand
to allow the track to spin.
7. Start the engine and apply enough throttle to spin the
track.
8. Turn off then engine, and repeat belt deflection
inspection.
D
Torque Limiter
NOTE: 2010 Models Only
Inspect the rubber dampener for signs of abnormal wear

and tear. Adjust the linkage length to specification.
1. Measure the belt deflection with both clutches at rest RUBBER DAMPENER
and in their full neutral position.
2. Place a straight edge across the tow clutches, on top
the belt.
3. Apply downward pressure to the belt and measure the
distance at point (D). Compare to specification.
(MM)

2.17
Maintenance
Clutch Alignment/Offset
The drive and driven clutches are offset from each other. Driven Clutch Offset/Shim Washers
This offset is controlled by the number and thickness of
washers installed on the jackshaft behind the driven Offset Washers
clutch. 16 Gauge Bushing=7556509 (QTY.1)
.023 = 7555917 (AR)
1. Remove drive belt. .120 = 7555864 (AR)
Float Washers
2. Push the driven clutch towards the bulkhead. Install .065" = 7555806 (AR)
the alignment tool into the drive clutch and on top of .105" = 7555832 (AR)
the driven clutch hub.
AR = As Required
TOOL PART NUMBER APPLICATION
PS-47477 Light Weight (LWT) Team Driven / P2

CAUTION
NOTE: The PS-47477 offset tool is calibrated with the
Always verify the driven clutch floats on the jackshaft.
correct alignment angle for the respective driven
The jackshaft bearing will fail from side-loading if the
clutch.
driven clutch is not allowed to float.
Inspect for broken motor mounts, engine straps or
bulkhead damage if the offset tool reveals major mis-
alignment.
0 - .060
3. The optimum setup is when the front and rear of the
tool touch the driven clutch. No gap should be present
in the front, and the rear clearance should not exceed PUSH CLUTCH
.060" (1.5mm).
NOTE: If the front of the alignment bar does not touch

the driven sheave, the maximum clearance cannot
exceed .025 (.64mm).
Offset/Float Adjustment
1. Determine direction driven clutch needs to be
adjusted.
2. Remove driven clutch retaining bolt, and remove
driven clutch. TOUCHING
3. With one 16 GA. bushing installed, add or remove
offset washers from behind the driven clutch to set the
proper offset.
4. After adjusting the offset, add or remove shim
washers from behind the driven clutch bolt and
washer to provide a .060" (.1.5mm) driven clutch float
on the jackshaft.
(PN: PS-46998 Shown)

Maintenance
Adjusting Engine Mount Bolts/Engine 4. Once clutch alignment is set, tighten the engine mount
Alignment bolts to specification in the sequence shown in the
illustration.
Minor adjustments to the engine mount bolts and MAG-
front engine mount can be performed if the alignment tool
indicates major clutch mis-alignment.
2
1. Loosen, but do not remove, the four engine mount
bolts. 4
3
2
1
=T
2010 - 14mm Head Diameter - DK.Green Color:
DK. GREEN-M10x1.5x45 (8.8) = 30 ft-lb (41 Nm)
2. Loosen, but do not remove, the two Torx screws 2011 - 14mm Head Diameter - Silver/Gray Color:
securing the MAG-front engine mount to the SILVER/GRY-M10x1.5x50 (12.9) = 35 ft-lb (48 Nm)
bulkhead.
2012/Replacement Kit - 16mm Head Diameter:
Silver/Gray Color
SILVER/GRY-M10x1.50 (12.9) = 40 ft-lb (54 Nm)
5. Torque the two Torx screws only after all four engine
mount bolts are torqued to specification.
=T
Front-MAG Engine Mount Screws-to-Bulkhead Screws:
22 ft-lb (30 Nm)
6. Re-check clutch alignment. If clutch alignment is still

incorrect, inspect the engine mounts, motor straps,
radial inserts, and chassis for broken or twisted
components.
3. Verify clutch alignment has changed using the Clutch

Alignment Tool part number: PS-47477. The engine
can be moved slightly with the screws loosened at the
MAG-front location.

2.19
Maintenance
FUEL/INTAKE SYSTEM 10. If the filter bracket was removed for any reason, note
that the fuel return hose p-clamp is installed behind
Fuel Filter - DC-CFI-4 Models the filter bracket.
11. Inspect the hoses making sure none are worn or
damaged.
WARNING
12. Reinstall the clutch cover. Torque cover nuts to
When removing the fuel filter fuel spillage will occur. Be specification.
sure to work in a well ventilated area away from 13. Reconnect the ECU wiring harness connectors.
anything which may cause the fuel to ignite such as an
open flame, heaters, trouble lights or cigarettes. 14. Install the ECU bracket onto the oil tank. Reinstall the
oil tank. Torque mount screw to specification.
1. The fuel filter should be replaced as outlined in the
15. Reinstall the drive belt. Replace the hood and door
periodic maintenance table.
panels.
2. Open the left and right door panels. Remove the hood
and drive belt. Fuel Filter - DC-CFI-2 Models
3. Disengage the rubber strap securing the oil tank to the
clutch cover. Remove the oil tank mount screw. WARNING
4. Remove the two harness connectors from the ECU.
Remove the oil tank fill cap, and then the ECU bracket. When removing the fuel filter fuel spillage will occur. Be
sure to work in a well ventilated area away from
5. Remove the four nuts that mount the clutch cover to
anything which may cause the fuel to ignite such as an
the chassis. Slide the oil tank down to open access to
open flame, heaters, trouble lights or cigarettes.
the two rear nuts.
6. Carefully release the clutch cover from the studs and 1. The fuel filter should be replaced as outlined in the
then pull it away from the airbox. periodic maintenance table.
7. De-pressurize the fuel system. Remove the filter from 2. Open the left and right door panels. Remove the hood
the airbox bracket. Disconnect the fuel filter from the and drive belt.
pump flange and supply fuel hose using a 3/8" fuel line
3. Disengage the rubber strap securing the oil tank to the
disconnect tool.
clutch cover. Remove the oil tank mount screw.
P-CLAMP 4. Remove the two harness connectors from the ECU.

Remove the oil tank fill cap, and then the ECU bracket.
5. Remove the four nuts that mount the clutch cover to
FILTER BRACKET
P-CLAMP the chassis. Slide the oil tank down to open access to
the two rear nuts.
6. Carefully release the clutch cover from the studs and
then pull it away from the airbox.
FUEL FILTER/SUPPLY
8. Drain any fuel in the hoses/filter into an appropriate

container, and then discard filter in accordance with
local rules and regulations.
9. When re-connecting the fuel hoses, verify an audible
click is heard and the connections are secure by
firmly pulling on the two hose connections. Push the
filter cartridge back into the bracket.

Maintenance
7. Depressurize the fuel system. Remove the filter from 12. Reconnect the supply hose to the fuel pump flange.
the airbox bracket. Disconnect the fuel supply hose Verify an audible click is heard and the connections
from the fuel pump flange using a disconnect tool. are secure by firmly pulling on the two hose
connections. Push the filter cartridge back into the
CLOSE COVER TO FUEL RETURN HOSE
SECURE RETURN HOSE
bracket.
13. Inspect the hoses making sure none are worn or
damaged.
2
14. Reinstall the clutch cover. Torque cover nuts to
specification.
15. Reconnect the ECU wiring harness connectors.
16. Install the ECU bracket onto the oil tank. Reinstall the
oil tank. Torque mount screw to specification.
FUEL FILTER MOUNTS HERE
17. Reinstall the drive belt. Replace the hood and door
panels.
Fuel Hose Inspection

8. Remove the bottom fuel fitting clamp on the fuel rail.
Inspect all fuel hoses as part of periodic maintenance.
9. Carefully remove the fuel hose fitting from the fuel rail.
Replace any fuel hose if the inner rubber core show signs
Have a clean shop rag at hand to absorb any fuel that
of wear.
leaks from the fitting. Dispose of rag properly when
finished. INNER RUBBER HOSE WORN = REPLACE FUEL HOSE
FUEL FILTER/SUPPLY
O-RINGS
CLAMP
SCREW
10. Drain any fuel in the hoses/filter into an appropriate

container, and then discard filter in accordance with
local rules and regulations.
11. Apply a light film of two stroke engine oil to the new
fuel supply hose fitting. Carefully install the fitting back
into the fuel rail. Torque screw to specification.
=T
Fuel Hose Fittings-to-Fuel Rail Clamp Screws:
3.3 ft-lb (4.5 Nm)

2.21
Maintenance
Fuel Tank Vent System Air Box/Pre-Filters
All models feature a fuel tank vent / vacuum check valve Inspect the air intake system as outlined in the periodic
system. maintenance table. Replace cracked, broken, or missing
parts.
The rollover check valve prevents fuel from escaping the
tank in the event of a vehicle rollover. Verify the hood intake screens are not torn or missing. An
intake tube connects the hood plenum to the air box inside
ROLLOVER VALVE
the engine compartment.
Always verify the intake tube is installed properly in both

the air box and hood plenum when installing the hood
assembly.
MESH SCREEN
HOOD
FOAM FILTER
The rollover check valve is not serviceable. When

inspecting the system, verify the hose is not kinked.
INTAKE PLENUM
VENT BRACKET
INTAKE TUBE
FOAM GASKET
BARRIER MAT
AIRBOX TOP
TRUMPETS
TRUMPET PLATE
BARRIER MAT
BARRIER MAT
AIRBOX BASE
BOOTS
BARRIER MAT
2010 Rush
GEAR CLAMPS

Maintenance
2011 and later models feature an air box with a revised Air Box Servicing
intake tube to reduce noise and a trumpet plate that is
screwed to the air box base. The air box can be removed from the engine compartment
by disassembling the individual components.
INTAKE FOAM
1. Remove the left and right door panels.
2
INTAKE TUBE
3. Remove the oil tank/clutch cover assembly.
4. Remove the intake tube from the airbox.
5. Un-hook the four air box top clamps. Remove the air
box top piece from the engine compartment.
INTAKE TUBE COVER
6. Remove the trumpet plate. On 2011-current models,
remove the screws securing the plate to the air box
base. Note the TOP FWD plate orientation marking
on the plate.
7. Loosen the two gear clamps securing the intake boots
SEAL
to the throttle body.
8. Carefully pull up on the rear of the air box base to
release the intake boots from the throttle body.
Remove the air box base from the engine
compartment.
AIRBOX TOP
TRUMPETS 9. Note the gear clamp stops on the intake boots. Ensure
the worm gear housings on each gear clamp are
positioned against the stops during assembly. (The
BARRIER MAT
stops prevent the gear clamps from rotating while
tightening.)
10. Air box installation is the reverse of removal. Verify the
intake boots are installed tight and flush against the
throttle body.
11. Install the trumpet plate with the TOP FWD call out
orientated correctly.
TRUMPETPLATE
BARRIER MAT 12. Verify the intake tube foam is not damaged or torn. If
it is, it must be replaced with new foam.
13. After installing the hood assembly, verify the intake
INTAKE BOOTS tube is installed in both the air box and hood intake
plenum.
BARRIER MAT

2.23
Maintenance
CHASSIS To remove the hood, follow these steps:
Door/Hood Removal and Installation 1. Remove both door panels.

2. Using a T40 Torx driver, remove the two screws
To remove the door panels, follow these steps:
securing the hood to the steering post.
1. Turn the two 1/4 turn fasteners counter-clockwise.
2. Un-hook the rubber strap. Carefully pull the door(s)
away from the hood/chassis.
1/4 TURN FASTENER 1/4 TURN FASTENER
3. Using a flat blade screwdriver, remove the left and

right side nylon rivets securing the hood to the
RUBBER STRAP
console.
3. Pull up on the door to disengage the locking tabs at

the bottom of each door.
LOCKING TABS
4. Disconnect the hood wiring harness from the chassis

harness. Note the routing of the harness under the
over structure tube.
5. Lift the back of the hood up making sure the brake duct
clears the console. Push the hood forward to
disengage the nose tabs from the nose cone.
6. Remove the hood from the vehicle.

Maintenance
7. When installing the hood, verify the hood harness 9. Prior to closing the left side door panel, verify the air
connector is routed under the over structure tube. box intake tube is installed in both the air box and hood
intake plenum.
PLENUM
INTAKE TUBE
2
HARNESS CONNECTOR
INTAKE TUBE
NOTE: The hood harness connector must be routed

under the over structure tube to prevent the wires
from coming into contact with the other components.
8. Engage the two console tabs with the hood plenum

slots at the rear of the hood.
AIR BOX
PLENUM
PLENUM SLOT
NOTE: Failure to properly install the intake tube may

cause snow or under hood hot air ingestion into the
intake system.
CONSOLE TAB
NOTE: Failure to properly install the console tabs

into the hood plenum may cause snow ingestion and
not allow the hood to seat correctly.

2.25
Maintenance
Chain Case Oil Level Check Drive Chain Tension Adjustment
Maintain the oil level at the bottom of the fill port hole. 1. Open the left and right side door panels. Remove the
hood.
1. Position the vehicle on a flat and level surface. 2. Remove the exhaust silencer.
2. Remove the fill plug. Verify the oil level is at the base 3. Rotate the driven clutch counter-clockwise to move all
of the plug hole. of the slack in the chain to the tensioner side. Set the
3. Add the recommended oil as needed at the fill plug. parking brake, or have an assistant hold the brake
lever.
4. Loosen the jam nut.
FILL PLUG
PLENUM
JAM NUT
ADJUSTER SCREW
5. Finger tighten the adjuster screw until it can no longer

Chain Case Oil Replacement be adjusted by hand, then back off 1/4 turn.
1. Locate the chaincase drain plug on the bottom of the 6. Tighten the jam nut while holding the adjuster bolt.
nosepan. torque to 21 ft-lb (28 Nm).
2. Place an oil catch pan under the drain plug. Clean the 7. Release the brake lever lock.
drain plug socket.
8. Reinstall the exhaust silencer.
3. Remove the drain plug and drain the oil into the catch
pan.
4. Clean the magnetic plug to remove metal shavings.
5. Install drain plug and hand-tighten. Do not over-
tighten the drain plug.
6. Remove the fill plug. Clean the magnetic end to
remove metal shavings. Fill chaincase with 80W
synthetic chaincase lubricant at the fill plug location
until the oil level is at the base of the threads.
Chaincase Oil Capacity = 9oz. (266 ml)

Recommended Lubricant:
Chaincase = Polaris 80W Synthetic
Chaincase Lubricant

Maintenance
Chain Case Fastener Re-Torque BRAKE SYSTEM MAINTENANCE
NOTE: This maintenance procedure only applies to Brake Lever Travel
2010-2011 models. 2012 models feature chain cases
that are bonded to the chassis.
Verify and re-torque the chain case mount screws as 2

outlined in the periodic maintenance table.
1/2 (1.3 CM)
The drive exhaust silencer will require removal to gain
access to two front chaincase mount screws.
C
The gap between the brake lever and handlebar grip
STUD PLATE
should be equal to or more than 1/2 (1.3cm) when
depressing the brake lever.
If the gap is less than 1/2 (1.3cm), the brake system

should be inspected and bled of any air within the fluid.
C
A
Brake Fluid
C WARNING
B
Do not over fill the master cylinder. Fluid expansion
C
could cause brakes to lock, resulting in serious injury or
death. Once a bottle of brake fluid is opened, use what
=T is necessary and discard the rest. Do not store or use
a partial bottle of brake fluid. Brake fluid is hygroscopic,
meaning it rapidly absorbs moisture from the air. This
A = 26 ft-lb (35 Nm) DO NOT OVER-TORQUE
causes the boiling temperature of the brake fluid to
B = 26 ft-lb (35 Nm)
drop, leading to early brake fade and the possibility of
C = 14 ft-lb (19 Nm)
serious injury
Inspect the reservoir to be sure it contains the correct

amount of fluid. Use only Polaris DOT 4 high temperature
brake fluid. Change fluid every 2 years or whenever the
fluid is dark or contamination is suspected.
NOTE: A low brake fluid level can be indicated

through the sight glass on the cover. If the fluid is low
this sight glass will glow a brighter. color.
LOW FULL

2.27
Maintenance
Brake Pad Replacement NOTE: Never use the in-line adjuster to adjust engine
idle speed. Never adjust the cable so that the throttle
Brake pads need to be replaced if the thickness of the plate cam on the throttle body no longer rests against
friction material is less than 1/16" (.0625") / 1.5mm. the idle air gap screw.
Brake Pad
Turning the in-line adjuster inwards (clockwise) will
increase throttle lever free-play.
Turning the in-line adjuster outwards (counter-clockwise)

will decrease throttle lever free-play.
After setting the throttle lever free play, always verify the oil
pump adjustment is set correctly.
Throttle Cable Routing

1/16(.0625") / 1.5mm
Route the throttle cable as shown in the photo. Turn the
handle bars to the full left and right positions with the
THROTTLE CABLE ADJUSTMENT engine running to verify the engine RPM does not increase
as the bars are turned.
Throttle Lever Free-Play
CAUTION
When adjusting throttle lever free-play, always verify the

engine RPM does not change while turning the
handlebars to the full left and full right positions.
= In. / mm.
Throttle Lever Free Play: .010 -.030 (0.25-0.8mm)
The inline adjuster should only be used to set free play and
to remove cable slack that occurs if the cable has
stretched over time.
ROUTE THROUGH
ROSEBUD
ADJUSTER
LOCK NUT

Maintenance
STEERING / SUSPENSION 3. Adjust handlebars to desired position. Verify the
MAINTENANCE wiring harness, brake hose, and throttle cable do not
kink.
Handlebars
NOTE: Verify FWD printed on riser faces front of
Periodically inspect the torque of the handlebar clamp
fasteners.
snowmobile
2
4. Secure the front clamp fasteners first to specification.
Finish by securing the two rear clamp fasteners to the
same torque setting.
A =T
Handlebar Clamp Fastener Torque:
HANDLEBAR
A = 14.7 ft-lb (20 Nm)
5. Reinstall the handlebar cover if equipped.
RISER (FWD FACES FRONT) Adjustable Riser

Periodically inspect the torque of the upper/lower
STEERING POST
handlebar clamp fasteners, and slide fasteners.
A A
A RUSH/SWITCHBACK/RMK
HANDLEBAR
CLAMP
A
A
STEERING POST
=T
Handlebar Clamp Fastener Torque:
A = 15.4 ft-lb (21 Nm) Apply Loctite 243
PRO RMK/RMK ASSAULT
ROX Slide Fastener Torque:
B = 15 ft-lb (20 Nm)
Adjuster Cranks: Hand Tight
1. To adjust the handlebar angle, remove the handlebar
cover, if equipped, to expose the upper clamp.
2. Loosen the four clamp fasteners. Slightly pry the
upper clamp up with a flat blade screwdriver.

2.29
Maintenance
Ski/Ski Skag Fasteners Track Tension
Periodically inspect the ski-to-spindle fasteners for proper Track tension is critical for maintaining correct suspension
torque. operation. If the track tension is too loose, the track may
SKI STOP (FRONT TO SKI TIP) bunch-up at the rail tips, or slip (ratchet). If the track is too
tight, premature rail slide wear, reduced top speed, rear
suspension vibration can occur.
SKI LOOP/HANDLE
A ADJUSTER SCREW(C)
JAM NUT(B)
D
B C
A
F TRACK
16 (41CM) 10 LBS. (4.54 kg)

E PROGRESSIVE 120/121
SKI SKAG/CARBIDE
=T ADJUSTER SCREW(C)
JAM NUT(B)
A = 36 ft-lb (50 Nm)
B = 6 ft-lb (8 Nm)
C = 7 ft-lb (10 Nm)
D = 9 ft-lb (12 Nm)
Inspect ski skags and skag fasteners for abnormal wear A

and tear. Replace skags when carbide edge is worn away
F TRACK
or when skag is bent/damaged.
16 (41CM) 10 LBS. (4.54 kg)
Always use new lock nuts when replacing parts. E SWITCHBACK 144/RMK COIL OVER
1. Lift the rear of the machine using a dedicated sled lift.
NOTE: A conventional track stand will not work for

adjusting track tension on PRO-RIDE Progressive
suspensions as lifting the sled at the bumper will
compress the rear crank and tighten the track.
2. Start the engine and slowly let the engine turn the
track over.
3. Shut off the engine.
4. Place a 10 lb. (4.54kg) weight at point (A). Point (A)
is 16 (41cm) ahead of the rear idler shaft (E).

Maintenance
5. Measure the distance between the rail slider and the Track Alignment
track. The measurement should fall within the
measurement range for the appropriate vehicle. NOTE: Track alignment affects track tension.
Misalignment of the track will cause excessive wear to
the track, rail slides, and rail.
SUSPENSION MEASUREMENT
Progressive 120 7/8 -1-1/8

Excessive rail slide wear occurs due to running in
inadequate snow conditions. 2
(2010 Rush) (2.2 - 2.9cm)
Periodically check that the track is centered and running
Progressive 121 1/2 - 1.0
evenly on the rails. Misalignment will cause excessive
(2011 Rush) (1.3 - 2.54cm)
wear to the track and slide rails.
Progressive 121/136 1/4 -3/8
(2012 Rush/Switchback) (6.3-9.5mm) 1. Safely lift and support the rear of the snowmobile off
the ground.
RMK/Switchback 144 3/8 - 1/2
RMK Coil Over 155/163 (1 - 1.3cm) 2. Rotate the track by hand to check for any possible
damage.
6. If adjustment is needed, loosen the jam nuts (B) on
each rail.
A
7. Loosen the idler shaft bolts (F).
8. Turn each adjuster screw equally (C) clockwise to
tighten track. Turn the adjuster screw equally
counterclockwise to loosen track tension.
9. Torque the jam nuts (B) and idler shaft bolts on each
side to 35 ft-lb (47.5 Nm).
3. Inspect the track rods (A) carefully and examine the

track along the entire length of each rod, bending the
track edge and inspecting it for breakage. If any rod
damage is found, the track should be replaced.
4. Warm up the track by starting the engine and apply a
small amount of throttle so the track runs slowly at
least five complete revolutions.
5. Stop the engine and turn the ignition off.
6. Inspect track alignment by carefully looking through
the track window (B) to make sure the rails (C) are
evenly spaced on each side.
7. If the track runs to the left, loosen the left locknut and
tighten the left adjusting bolt. If the track runs to the
right, loosen the right locknut and tighten the right
adjusting bolt. It may be necessary to check this with
the engine rotating the track. Be sure to SHUT THE
MACHINE OFF before making any further
adjustments.
8. Loosen up the rear idler shaft.

2.31
Maintenance
9. After any adjustments are complete, be sure to torque Progressive 121
the locknuts to specification.
=T
Adjuster Lock Nuts: 33 ft-lb (45 Nm)
10. Torque both idler shaft bolts to specification.
=T
Idler Shaft Bolt: 33 ft-lb (45 Nm)
WARNING
BUSHING LOCATION
Broken track rods can cause a rotating track to come off

the machine. Never operate or rotate a damaged track Suspension Lubrication
under power with broken rod(s). Serious injury or death
may occur. Lubricate the rear suspension pivot shafts with Polaris
Stay clear of all moving parts to avoid personal injury. Premium All Season Grease as outlined in the periodic
Never make any adjustments with the engine running, maintenance table.
as serious personal injury can result.
Progressive 121/136
Suspension Pivots/Lubrication
Inspect suspension pivot bushings as outlined in the
periodic maintenance table. Replace worn or damaged
bushings.
Progressive 120
GREASE ZERK
BUSHING LOCATION

Maintenance
Switchback/RMK 144 ELECTRICAL SYSTEMS
! Headlight Bulb Replacement
! NOTE: Do not touch the bulb with your fingers. The
grease from body oil will cause a hot spot on the bulb
and cause bulb failure. If you do touch the bulb clean 2
the bulb with isopropyl alcohol.

2. Locate the bulb connectors on the head lamp
assembly.
! 3. Rotate the connector counter-clockwise to remove
the bulb.
GREASE ZERK 4. Install a new bulb by holding it in a clean shop rag or
!
napkin.
RMK Coil Over 155/163 5. Install the connector into the head lamp and turn
clockwise.
6. Reinstall the hood assembly.
Tail Lamp Replacement

The rear tail lamp assembly uses light emitting diodes
(LEDs). LEDs cannot be replaced. The tail lamp assembly
must be replaced if an LED is not functioning.
GREASE ZERK

2.33
Maintenance
OFF-SEASON STORAGE Corrosion
To prevent corrosion, always grease jackshaft and drive
Chassis And Hood
shaft (clutch side) bearings with Polaris Premium all
Proper storage starts by cleaning, washing and waxing the season grease. Loosen driven clutch retaining bolt and
hood, chassis, upholstery and plastic parts. Clean and pull clutch outward to expose bearing. Use a point type
touch up with paint any rusted or bare metal surfaces. grease gun fitting to inject grease through hole in flangette
Ensure that all corrosive salt and acids are removed from into bearing until grease purges out inside or outside
surfaces before beginning preservation with waxes and bearing seal. Push clutch back on shaft and replace clutch
rust inhibitors (grease, oil, or paint). retaining bolt. Inject grease into fitting on speedometer
drive adaptor until grease purges out inside or outside the
If the machine is equipped with a battery, disconnect the bearing seal. Lubricate both front ski pivots at bushings
battery cables and clean the cables and battery posts. Fill and spindles.
battery to proper level with distilled water and charge to full
capacity. Remove and store the battery in a cool dry place. Shocks
The machine should be stored in a dry garage or shed out Use T-9 Metal Protectant (or equivalent) on shock
of the sunlight and covered with a fabric snowmobile absorber shafts to help prevent corrosion.
cover. Do not use plastic to cover the machine; moisture
will be trapped inside causing rust and corrosion Battery
problems.
Disconnect and remove the battery. Clean the terminals
and cables. Apply dielectric grease to the terminals. Store
Clutch And Drive System
in a cool dry place for storage.
Remove drive belt and store in a cool dry location.
Lubricate sheave faces and ramps of drive and driven
clutches with light oil or rust inhibitor. All lubrication applied
as a rust preventative measure must be cleaned off before
installing belt for service and operating machine.
Controls And Linkage

All bushings, spindle shafts and tie rod ends should be
coated with a light coat of oil or grease. Throttle controls
and cables should be lubricated. Force a small amount of
lubricant down cables.
Electrical Connections
Separate electrical connector blocks and clean corrosive
build-up from connectors. Lubricate or pack connector
blocks with Nyogel grease and reconnect. Replace
worn or frayed electrical wire and connectors.
Carburetor/Throttle Body
Fog engine with Polaris Fogging Oil (aerosol type)
according to directions on can.
Fuel System
Treat the fuel system with Polaris Carbon Clean. If Polaris
Carbon Clean is not used, fuel tank, fuel lines, and
carburetor should be completely drained of gasoline.

Engine/Cooling/Exhaust
CHAPTER 3
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3
FASTENER TORQUE GUIDE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.3
COMPONENT TORQUE SEQUENCES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.4
ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.5
3
ENGINE SERVICE SPECIFICATIONS - ALL ENGINES . . . . . . . . . . . . . . . . . . . . . . . . .3.5
VEHICLE/ENGINE MATRIX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.6
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
SPECIAL TOOLS - ENGINE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.7
ENGINE INSPECTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7
CYLINDER HEAD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.7
CYLINDER MEASUREMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.8
PISTON INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9
PISTON RING INSTALLED GAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.9
REED VALVE INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10
BEARING FIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.10
CRANKSHAFT RUNOUT INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11
MAIN BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11
CONNECTING ROD LOWER BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.11
PISTON NEEDLE BEARING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.12
CRANKSHAFT INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.13
CHECKING CRANKSHAFT INDEX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.13
CYLINDER HONING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.14
HONING TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.14
HONING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.14
CLEANING THE CYLINDER AFTER HONING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.14
CRANKSHAFT TRUING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.15
ENGINE MOUNTING SYSTEMS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
2010 600 ENGINE MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.16
2011 600 ENGINE MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.17
2011 800 ENGINE MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.18
2012 600/800 ENGINE MOUNTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.19
ENGINE MOUNT BOLT SERVICE REPLACEMENT KIT. . . . . . . . . . . . . . . . . . . . . . . .3.20
ENGINE MOUNT SCREW INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.20
RECOIL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21
ROPE REMOVAL AND INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.21
ENGINE COMPONENT ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.22
600 CYLINDER HEAD/CYLINDERS/PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.22
600/800 RECOIL/STATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.24
600 CRANKCASE/CRANKSHAFT ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.26
800 DC-CFI-2 CYLINDER HEAD/CYLINDER/PISTONS . . . . . . . . . . . . . . . . . . . . . . . .3.28
CYLINDER HEAD/CYLINDER/PISTON NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.29
800 DC-CFI-2 CYLINDER HEAD/CYLINDER/PISTONS DISASSEMBLY/ASSEMBLY .3.29
800 DC-CFI-2 CRANKCASE/CRANKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.30
800 DC-CFI-2 CRANKSHAFT IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.31
600/800 DC-CFI WATER AND OIL PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . .3.32
OIL HOSE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.34
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.35
ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .3.38

3.1
COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
THERMOSTAT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
THERMOSTAT ORIENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
800 THERMOSTATS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41
2010 600 RUSH COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.42
2012 600 RUSH/SWITCHBACK COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45
2012 800 RUSH/SWITCHBACK COOLING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46
PRO-RIDE SWITCHBACK ASSAULT/RMK COOLING SYSTEM . . . . . . . . . . . . . . . . . 3.47
PRO-RIDE PRO RMK/RMK ASSAULT COOLING SYSTEM. . . . . . . . . . . . . . . . . . . . . 3.48
FRONT HEAT EXCHANGER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.49
EXHAUST SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.50
PRO-RIDE DC-CFI-4 EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.50
PRO-RIDE DC-CFI-2 EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.51
VARIABLE EXHAUST SYSTEM (VES)-THREADED VALVE . . . . . . . . . . . . . . . . . . . . 3.52
VARIABLE EXHAUST SYSTEM (VES)-THREADED STUD . . . . . . . . . . . . . . . . . . . . . 3.53

ENGINE SPECIFICATIONS
Fastener Torque Guide
600 DC-CFI-2/4 800 DC-CFI-2

COMPONENT ASSEMBLY NOTES
FT-LB (NM) FT-LB (NM)
Spark Plug 18-21.6 (24-30) Apply anti-seize to threads.

Head Cover 23-27 (31.2-36.6)
Throttle Body Hose 7 (9.5) Apply pipe sealant to threads. 3
Plug-OR- 15.5-20 (21-27.8)
N/A
Bypass Nozzle 18 (24) Apply pipe sealant to threads.
Bleed Screw 70 in-lb (8 Nm)
Knock Sensor 144-192 in-lb (16.3-21.7Nm) Do not under/over torque. Clean/dry threads.
Temp. Sensor 18 (24)
EV Housing Base / Cover 10.5-13.5 ft-lb (14.3-18.3 Nm) Apply Loctite 242 to cylinder screws.
EV Bellows
-Cap Nut 14-18 ft-lb (19.1-24.5 Nm) Apply Loctite 242 to guillotine threads.
-Threaded Cap/Stud 18-22 ft-lb(24.5-29.9 Nm) Apply Loctite 242 to stud threads.
Cylinder Base Nuts 38-46 (51-62) N/A
Cylinder Bolts N/A 38-46 (51.6-62.4)
Intake Boots 9 (12)
Exhaust Manifold 22 (30)
Oil Pump 10 (9.5)
Water Pump Cover 9 (12)
Water Pump Cover
18 (24) Apply pipe sealant to threads.
Nozzle
Recoil Housing 9 (12)
Recoil Reel Screw
1204173 Assembly 9 (12) Apply Loctite 242 to threads.
1204331 Assembly 14 (20)
Recoil Hub Screws 9 (12)
Flywheel Nut 90 (122)
Stator Plate 12 (16)
Crankcase
22 (30)
M6/M8
Torque Stop Bracket 18 (24)
Engine Strap Screws 30 (41) Apply Loctite 242 to threads.
Water Pump Impeller 10 (13)
Fuel Rail Screws 9 (12)
Crankcase Drain Plugs 60 in-lb (7 Nm) Apply pipe sealant to threads.
Air Intake Gear Clamps 11 in-lb (1.2 Nm)

3.3
Component Torque Sequences CFI Recoil Cover
Cylinder Head Torque Pattern
MAG PTO
Cylinder Head Torque Pattern (Monoblock)
MAG PTO
CFI Crankcase Torque Pattern
MAG PTO
Cylinder Torque Pattern
MAG PTO
Cylinder Torque Pattern (Monoblock)
MAG PTO

Engine Specifications
PISTON-TO-
INSTALLED HEAD PISTON RING END TRIGGER-TO-
ENGINE MODEL HEAD SQUISH CYLINDER
VOLUME GAP FLYWHEEL GAP
NUMBER INCHES (MM) CLEARANCE
(CC) INCHES (MM) INCHES (MM)
INCHES (MM)
.014-.020
S4202-6044-OP6N
(0.356-0.508)
S4357-6044-OL6N
S4215-6044-OO6N
25.65-27.15
.045-.058
(1.143-1.482)
.0033-.0054
(0.085-0.137)
3
SVC. Limit=.009"
S4316-6044-OL6G
S4452-6044-OL6G
.014-.052
S4139-8044-OO8G .017-.025 (0.36-1.34)
S4229-8044-OO8G (0.450-0.650)
S4092-8044-OO8G .004-.0055
.054-.066
36.2-37.8 (0.103-0.141)
S4359-8044-OL8G (1.382-1.666)
SVC. Limit=.009"
S4360-8044-OL8G
S4361-8044-OL8G
Engine Service Specifications - All Engines

Cylinder Head Warp Limit = .006" (.015mm)
Cylinder Taper Limit = .002" (.051mm)
Cylinder Out-of-Round Limit = .002" (.051mm)
Main Bearing Interference Fit:
CFI = .0014 - .0024 (.036 - .061mm)
Connecting Rod Side Clearance = .0114" - .0295"
(.289 - .749mm)
Crankshaft Runout Deflection Limit = .0025"
(0.07mm)

3.5
Vehicle/Engine Matrix
MODEL YEAR VEHICLE ENGINE MODEL NUMBER
2010 600 Rush S4202-6044-OP6N

600 Rush/Rush LX/Rush Pro-R S4215-6044-OO6N
800 Rush/Rush LX/Rush Pro-R S4139-8044-OO8G
2011 800 Switchback 1.3/2.0

S4229-8044-OO8G
800 RMK 155
800 RMK Assault
S4092-8044-OO8G
800 PRO RMK 155/163
600 Rush/Rush Pro-R/600 Switchback/Adventure/Switchback Pro-R S4357-6044-OL6N
800 Rush/Rush Pro-R/Pro-R LE/800 Switchback/Switchback Pro-R S4360-8044-OL8G
Switchback Assault 1.3/2.0
S4361-8044-OL8G
800 RMK 155
2012
600 RMK 144/155 S4316-6044-OL6G
600 PRO RMK 155 S4452-6044-OL6G
800 RMK Assault
S4359-8044-OL8G
800 PRO RMK 155/163

SPECIAL TOOLS ENGINE INSPECTIONS
Special Tools - Engine Cylinder Head Inspection
Special Tools - Engine
PART NUMBER DESCRIPTION NOTE
Use to re-surface cylinder walls

2870303-A Ammco Hone Kit when installing new piston and/or
3
rings.
Provides better crosshatch

2870588 Hone Oil
pattern when honing cylinders.
Use to re-surface plated big bore

PU-49876 Ammco 320 Grit Stone
cylinders.
Supports piston when installing

2870390 Piston Support Block
pin and c-clips.
2871043-A Flywheel Puller

Using a precision straight edge and a feeler gauge, to
PU-45255 22mm Piston Pin Puller 800 CFI Engines inspect cylinder head for warping. Replace head if
Offset Piston Pin Puller warping exceeds .006" (.015mm).
PS-47055 800 CFI Engines
Adapter
2870386 Piston Pin Puller
2871445 Pin Puller Adapter Use with 2870386. = In. / mm.

Removes tabbed rubber engine
2871989 Engine Mount Socket
mounts.
Water Pump Seal Used to install water pump seal

Cylinder Head Warp Limit
2872389 .006" (.015mm)
Installation Tool on all 600/700/ 800 engines.
Install c-clips on all 600 / 700

2872401-A 20mm C-Clip Tool
engines.
2872622A 22mm C-Clip Tool Install c-clips on all 800 engines.
Use to loosen or tighten oil pump

PS-49001 Oil Cable Wrenches
cable jam nuts.
Battery Powered Timing

2870630 Check ignition timing.
Light
14mm Compression
2870852
Gauge
PU-45149 Hose Pincher
PU-45419 Strap Wrench Secure drive clutch or flywheel.
Use to inspect cylinder bore

PU-45423 Telescoping Gauge Set
diameter.
Use to measure run-out, piston

PU-45424 Dial Indicator Set
degrees-to-TDC, etc.
PV-39776 Electronic Digital Caliper
PU-45433 Seal Pick Set
PU-45431 Depth Micrometer Set
PV-34673 Precision Straight Edge
PV-43554 V-Block Set
Use to measure piston diameter,

PV-3009 75 - 100mm Micrometer
etc.
VES threaded stud/cap Use to clamp VES threaded stud/

PS-50753
tool. cap in bench vise.
NOTE: Polaris dealers can order the tools listed

above through the SPX Service Tools catalog or by
calling SPX @ 1-800-328-6657.

3.7
Cylinder Measurement
Inspect cylinder for wear, scratches, or damage. If no
damage is evident, measure the cylinder for taper and out
of round with a dial bore gauge. Measure the bore 20mm
from the top of the cylinder; in line with the piston pin and
90 to the pin to determine if the bore is out of round.
Repeat the measurements at a point just above the
exhaust port and at a point below the transfer port. Use the
chart below and record all measurements.
NOTE: A dial bore gauge is the only recommended

tool to accurately measure cylinder bore diameter.
= In. / mm.
Taper Limit: .002" (0.051mm)

Out-of-Round Limit: .002" (0.051mm)
Cylinder Measurement Worksheet

TOP (Measured 20mm from top of cylinder)
X Y
MIDDLE (Measured above exhaust port)

X Y
BOTTOM (Measured below transfer port)

X Y
Out-of-Round = Top X - Top Y and Bottom Y - Bottom X

Taper = Top Y - Bottom Y and Top X - Bottom X

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

diameter at a 90 angle to the direction of the piston pin
and at the specified measuring point. Position the ring 20mm from the top of the cylinder using
the piston to push it squarely into place. Measure installed
NOTE: A micrometer is the only recommended tool to
accurately measure piston diameter.
gap with a feeler gauge at both the top and bottom of the
cylinder. 3
NOTE: A difference in end gap indicates cylinder
taper. The cylinder should be measured for excessive
taper and out-of-round. Replace rings if the installed
end gap exceeds the service limit. Always check
piston ring installed gap after re-boring a cylinder or
when installing new rings.
Piston rings are installed with marking or beveled side up.
MEASURING
POINT
= In. / mm.
Measuring Point
600/800 Pistons: 10-20mm
Subtract this measurement from the minimum cylinder

measurement (90 to the pin). If clearance exceeds the
service limit piston/cylinder overhaul may be required.

3.9
Reed Valve Inspection Bearing Fit
1. Loosen the hose clamps. Any time crankshaft bearing failure occurs and the case is
2. Remove the throttle body from the intake boots. reused, check the bearing fit into the case halves using the
3. Remove the intake boot fasteners. following procedure.
4. Remove the intake assembly. With case halves cleaned, reinstall the main bearings with
5. Separate the intake boot from the reed cages. a piece of Plastigage between the bearing race and
6. Separate the reed stuffer(s) from the reed cage and crankcase.
inspect the reeds before they are removed from the
reed cage. Install and torque the crankcase fasteners to
specification. Take the crankcase apart, and then
NOTE: Measure the air gap between the fiber reed and the measure the Plastigage. Compare Plastigage width to
reed block. The air gap should not exceed .015" (.38mm). If interference fit specification.
clearance is excessive DO NOT attempt to reverse the reeds
to reduce the air gap. Always replace them if damaged or
worn. Check each fiber reed for white stress marks or
missing material.
The air gap should not exceed.015 (0.30mm)

= In. / mm.
.061mm)
Bearing Interference Fit:

.0014" - .0024" (0.035-0.061mm)
7. Inspect the leading edges of each reed pedal. If edges

are chipped, or excessively worn, replace the reed
assembly.
INSPECT EACH PEDAL EDGE FOR DAMAGE

Crankshaft Runout Inspection Connecting Rod Lower Bearing
3
1. Support the crankshaft in a set of V blocks as shown.
2. Use a dial indicator to measure the runout at the
following locations:
Measure connecting rod big end side clearance with a
PTO end = First taper after bearing flat. feeler gauge on both sides of the connecting rod. The side
MAG end = 1/2" from bearing flat. clearance on either side of the connecting rod cannot
3. Runout deflection cannot exceed .0025" (.07mm). exceed the connecting rod side clearance specification.
4. If the runout deflection exceeds the maximum The difference between the two clearance measurements
specification, crankshaft trueing may correct the cannot exceed the maximum clearance differential
deflection. specification.
Main Bearing
= In. / mm.
Clean crankshaft thoroughly and oil main and connecting
rod bearings with Polaris engine oil. Carefully check each
main bearing on the crankshaft. Connecting Rod Side Clearance:
.0114"-.0295" (0.289-0.749mm)
Due to extremely close tolerances, the bearings must be Maximum Clearance Differential
inspected visually and by feel. Look for signs of .002" (0.051mm)
discoloration, scoring or galling. Turn the outer race of
each bearing. The bearings should turn smoothly and Rotate the connecting rod on the crankshaft and feel for
quietly. The inner race of each bearing should fit tightly on any rough spots. Check radial end play in rod by
the crankshaft. The outer race should be firm with minimal supporting rod against one thrust washer and alternately
side to side movement and no detectable up and down applying up and down pressure. Replace bearing, pin, and
movement. Replace any loose or rough bearings. thrust washers if side clearance is excessive or if there is
any up and down movement detectable in the big end
bearing.

3.11
Piston Needle Bearing
1. Clean the end of the connecting rod and inspect inner
bore with a magnifying glass. Look for any surface
irregularities including pitting, wear, or dents.
2. Run a fingernail around the inside of the rod and check
for rough spots, galling, or wear.
3. Oil and install needle bearing and pin in connecting
rod.
4. Rotate pin slowly and check for rough spots or any
resistance to movement.
5. Slide pin back and forth through bearing while rotating
and check for rough spots.
6. With pin and bearing centered in rod, twist ends back

and forth in all directions to check for excessive axial
play.
7. Pull up and down evenly on both ends of pin to check
for radial play.
8. Replace pin and bearing if there is any resistance to
rotation or excessive axial or radial movement. If play
or roughness is evident with a new pin and bearing,
replace the connecting rod.

Crankshaft Index 3. With a section of wire (wire coat hanger), anchor it to
a convenient spot. Bend one end at the outer
Polaris crankshafts are pressed together. The connecting perimeter of the degree wheel as shown below.
rod journal center lines are indexed 180 apart from each
4. Install a dial indicator into the magneto end cylinder
other.
spark plug hole. The ignition timing is referenced by
the magneto end.
It is sometimes necessary to check multi-cylinder
crankshafts to verify that one cylinder has not been forced 5. Locate TDC as accurately as possible by finding the
out of position relative to the other cylinder. Some causes center of the point where there is no piston movement
for a out of index crankshaft include but are not limited to note the Zero the dial indicator at this point.
the following: 6. Continue to rotate the crankshaft in the normal
direction of rotation until the dial indicator reads .100" 3
Hydrolock from water or fuel (2.54mm) after top dead center (ATDC).
Impact to drive clutch from object or accident 7. Bend the pointer or move the degree wheel until the
Abrupt piston or other mechanical failure pointer aligns with a 180 mark on the degree wheel.
Engine lock-up due to drive belt failure 8. With the pointer aligned, make sure the degree wheel
and pointer are secured and will not move out of
Symptoms of an out of index crankshaft can include but position. Re-check accuracy of this location a few
are not limited to the following: times. The pointer should align with the 180 mark
when the dial indicator reads .100 (2.54mm) ATDC.
Unexplained piston failure on one cylinder (i.e.
severe detonation, broken ring lands, etc.) NOTE: Do not move the crankshaft, degree wheel or
Excessive vibration of engine, back-firing, etc. pointer after the initial setting on the MAG end
Rough idle, poor top speed. cylinder - simply read the wheel and dial indicator.
Checking Crankshaft Index 9. Remove the dial indicator and install in PTO cylinder.
Repeat finding TDC process. Note the degree wheel
1. Remove the drive belt and drive clutch. indication when the dial indicator reads .100" ATDC.
2. Securely fasten a large degree wheel on the flywheel It should be 180 (+/-2) from the MAG cylinder mark.
or PTO end of the crankshaft. Make sure that it is
mounted concentrically with the crankshaft center
line.

3.13
Cylinder Honing Honing Procedure
The cylinder bore must be de-glazed whenever new 1. Wash the cylinder with cleaning solvent.
piston rings are installed. A light honing with fine stones 2. Clamp the cylinder in a soft jawed vise by the cylinder
removes only a very small amount of material. A proper studs.
crosshatch pattern is important to provide a surface that 3. Place hone in cylinder and tighten stone adjusting
will hold oil, and allow the rings to seat properly. If the knob until stone contacts the cylinder walls (DO NOT
crosshatch is too steep, oil retention will be reduced. A OVERTIGHTEN).
crosshatch angle which is too shallow will cause ring 4. Apply honing oil to the stones and cylinder walls. Wet
vibration, poor sealing, and overheating of the rings due honing removes more material faster and leaves a
to blow-by and reduced contact with the cylinder wall. more distinct pattern in the bore.
Service life of the pistons and rings will be greatly
5. Using a 1/2" (13 mm) drill motor rotating at a speed of
reduced.
300-500 RPM, run the hone in and out of the cylinder
rapidly until cutting tension decreases. Remember to
NOTE: A Nicasil cylinder can be lightly honed with a
keep the hone drive shaft centered to prevent edge
320 grit stone hone but can not be oversized.
loading and always bring the stone approximately 1/
2" (1.2 cm) beyond the bore at the end of each stroke.
6. Release the hone at regular intervals to inspect bore
size and finish.
Cleaning The Cylinder After Honing

It is very important that the cylinder be thoroughly cleaned
after honing to remove all grit material. Wash the cylinder
in a solvent, then in hot soapy water. Pay close attention
to areas where the cylinder sleeve meets the aluminum
casting (transfer port area). Use electrical contact cleaner
if necessary to clean these areas. Rinse thoroughly, dry
with compressed air, and oil the bore immediately with
Polaris Premium 2 Cycle Lubricant.
EXAMPLE OF A CROSS HATCH PATTERN
NOTE: Always check piston to cylinder clearance
Honing Tools and piston ring installed gap after honing is complete.
The following tools are recommended:
Ammco 3950 Hone Kit - SPX PN 2870303 /

commercially available
Ammco 3956 Honing Stones (320 grit / Oversize)
Honing Oil - Commercially Available

Crankshaft Truing illustrations below. Use Crankshaft alignment kit PN
2870569.
Lubricate the bearings and clamp the crankshaft securely
in the holding fixture. If truing the crankshaft requires NOTE: The rod pin position in relation to the dial
striking with a hammer, always be sure to re-check indicator tells you what action is required to
previously straightened areas to verify truing. Refer to the straighten the shaft.
Truing Examples
To correct a situation like this. Strike the shaft at

point A with a brass hammer.
To correct a situation like the one shown in this.

Squeeze the crankshaft at point A. You will use the
tool from the alignment kit PN 2870569.
If the crank rod pin location is 180 from the dial

indicator (opposite of above), it will be necessary to
spread the crankshaft at the A position as shown in
illustration 3. When rebuilding and straightening a
crankshaft, straightness is of utmost importance.
Runout must be as close to zero as possible.

3.15
ENGINE MOUNTING SYSTEMS
2010 600 Engine Mounting
ENGINE ASSEMBLY TORQUE LINK INNER

C BRACKET
TORQUE LINK
C
E
A TORQUE LINK OUTER
D BRACKET
RADIAL INSERT (LARGE) TORQUE LINK MOUNT

A
C MOUNT BRACKET
A MOUNT
ENGINE MOUNTS
C B
MOUNT BRACKET
B
C C MOUNT W/CLINCH NUT
MOUNT B RADIAL INSERT (SMALL)
A B
A B
RADIAL INSERT (SMALL)

F F
NOTE: SEE ENGINE MOUNT BOLT SERVICE REPLACEMENT KIT F MOUNT W/CLINCH NUT
ENGINE MOUNT BOLTS-Note two torque values

=T for screws. Always clean engine mount threads
with compressed air or M10x1.5 tap before
A= installing screw(s). Apply Loctite 242 when
DK. GREEN-M10x1.5x45 (8.8) = 30 ft-lb (41 Nm) using original screw.
SILVER/GRY-M10x1.5x50 (12.9) = 35 ft-lb (48 Nm) To prevent the engine mount screws from catching
B = 9 ft-lb (12 Nm) on the radial inserts, spray the inserts with rubber
C = 26 ft-lb (35 Nm) lubricant or isopropyl before installing engine
D = 18 ft-lb (24 Nm) mount fasteners.
E = 12.5 ft-lb (17 Nm) Replace lock nuts with new parts when removed.
F = 30 ft-lb (41 Nm) Apply Loctite 242 to threads. Torque link length (center-to-center) = 3.33"
(84.63mm)
Assembly Notes:

TORQUE LINK INNER

BRACKET
C
ENGINE ASSEMBLY
3
TORQUE LINK OUTER
BRACKET
TORQUE LINK
C
D
E(NO Loctite)
TORQUE LINK MOUNT
RADIAL INSERT (LARGE)
A MOUNT BRACKET
A C MOUNT
ENGINE MOUNTS
C B
MOUNT BRACKET
C C MOUNT W/CLINCH NUT
B RADIAL INSERT(SMALL)
MOUNT
A B
A
B
B
E RADIAL INSERT(SMALL)
E E
MOUNT W/CLINCH NUT
E
NOTE: SEE ENGINE MOUNT BOLT SERVICE REPLACEMENT KIT
before installing screw(s). Apply Loctite 242

=T when using original screw.
To prevent the engine mount screws from catching
A = 35 ft-lb (48 Nm) Apply Loctite 242 to on the radial inserts, spray the inserts with rubber
threads. lubricant or isopropyl before installing engine
B = 9 ft-lb (12 Nm) mount fasteners.
C = 26 ft-lb (35 Nm) Replace lock nuts with new parts when removed.
D = 18 ft-lb (24 Nm)
E = 30 ft-lb (41 Nm) Apply Loctite 242 to threads.
Assembly Notes:
ENGINE MOUNT SCREWS-Always clean engine

mount threads with compressed air or M10x1.5 tap

3.17
C
ENGINE ASSEMBLY
TORQUE LINK INNER
BRACKET
TORQUE LINK OUTER

BRACKET
TORQUE LINK
C
E(NO Loctite)
TORQUE LINK MOUNT

MOUNT BRACKET
A
A
C MOUNT
B
C
ENGINE MOUNTS
MOUNT BRACKET C
C MOUNT W/CLINCH NUT
B RADIAL INSERT (LARGE)
MOUNT
A B
A
E RADIAL INSERT (SMALL)

MOUNT W/CLINCH NUT (PTO-SMALL)
E E
NOTE: SEE ENGINE MOUNT BOLT SERVICE REPLACEMENT KIT E
M10x1.5 tap before installing screw(s). Apply
=T Loctite 243 when using original bolt.
To prevent the engine mount bolts from catching
D = 18 ft-lb (24 Nm)
Assembly Notes:
ENGINE MOUNT BOLTS-Always clean engine

mount strap threads with compressed air or

2012 600/800 Engine Mounting
ENGINE ASSEMBLY
TORQUE LINK INNER
BRACKET
TORQUE LINK OUTER

3
BRACKET
TORQUE LINK
C
E(NO Loctite)
TORQUE LINK MOUNT

MOUNT BRACKET
A
A
C MOUNT
B
C
ENGINE MOUNTS
MOUNT BRACKET C
C MOUNT W/CLINCH NUT
B RADIAL INSERT (LARGE)
MOUNT
A B
A
E RADIAL INSERT (SMALL)

MOUNT W/CLINCH NUT (PTO-SMALL)
E E
E
M10x1.5 tap before installing screw(s). Apply
=T Loctite 243 when using original bolt.
To prevent the engine mount bolts from catching
D = 18 ft-lb (24 Nm)
Assembly Notes:
ENGINE MOUNT BOLTS-Always clean engine

mount strap threads with compressed air or

3.19
Engine Mount Bolt Service Replacement Kit IMPORTANT: It is recommended that all engine
mount bolts be replaced if removed. If bolt
A service kit has been developed to replace the original replacement is not possible, the bolt(s) must be
engine mount fastener bolts used on 2010-2011 600/800 replaced after TWO installation cycles. It is
Pro-Ride vehicles to the 2012 fastener specification. recommended that the technician marks the bulkhead
to count the number of installations at each bolt(s)
location.
Engine Mount Bolt Replacement Kit
PN 2204633 Engine Mount Screw Installation
1. Determine which bolt(s) is going to be installed.
The engine mount bolt replacement kit includes the
following parts: NOTE: Polaris recommends installing the Engine
Mount Bolt Replacement Kit (PN 2204633) if original
PN 7519334 - 4QTY. - Bolts-M10X1.5X50 12.9 2010-2011 bolts are installed.
PN 3022426 - 2QTY. - Radial Inserts (Small) 2. Clean the engine mount strap threads with
(600/800s - Front PTO / 2010-2011 600s Rear compressed air and/or M10x1.5 tap.
PTO ONLY)
3. Apply Loctite 243 or Loctite 242 w/Primer N
PN 3022409 - 3 QTY. - Radial Inserts (Large)
to 5-6 bolt threads.
(600/800s - MAG Front and Rear / 2011 800 Rear
PTO) 4. Reference torque specifications and install bolt(s).
5. Apply final torque to bolt(s) using the following order:
The engine mount bolt replacement kit will replace all four
engine mount bolts along with their associated radial Loosen already-installed bolts 1 full turn to accommodate
inserts. The original bolts (part numbers: 7519009 and torque pattern if required.
7519282) will sub to the 2204633 kit part number.
PTO-REAR
Bolt identification can be quickly made by measuring the PTO-FRONT
head diameter of the bolt. Bolts used on 2010-2011 Pro- MAG-REAR
Ride vehicles have 14mm head diameters, while the MAG-FRONT
replacement bolts have 16mm heads and feature a
knurled edge.
=T
2010 - 14mm Head Diameter - DK.Green Color
DK. GREEN-M10x1.5x45 (8.8) = 30 ft-lb (41 Nm)
2011 - 14mm Head Diameter - Silver/Gray Color

SILVER/GRY-M10x1.5x50 (12.9) = 35 ft-lb (48 Nm)
2012/Replacement Kit - 16mm Head Diameter

Silver/Gray Color
SILVER/GRY-M10x1.50 (12.9) = 40 ft-lb (54 Nm)
A selection of radial inserts is included with the kit. All
2010-2011Pro-Ride MAG-side engine mounts use large
radial inserts.
On the PTO side, all 2010-2011 600 Pro-Ride models use

small radial inserts in both the front and back locations.
All 2011 800 Pro-ride models feature a small PTO-front

and large PTO-rear radial insert.

RECOIL ASSEMBLY
Rope Removal and Installation
RECOIL HUB
SCREWS
TAB (ENGAGES INSIDE PULLEY)
FRICTION SPRING
HANDLE
ROPE SCREW\
3
FRICTION PLATE
RATCHET GUIDE
ROPE GUIDE (HOLE) RATCHET
COVER REEL RETURN SPRING
BUSHING
SCREWS
RECOIL SPRING
TAB (ENGAGES INSIDE HOUSING)
grease.
=T 7. Wind the rope counterclockwise around the pulley as
viewed from the ratchet-side of the reel.
Cover/Hub Screws: 9 ft-lb (12Nm) 8. Pass the end of the rope through the hole in the
Friction Plate Screw: housing. If the rope guide was removed from the
1204173 Recoil Assembly: 9 ft-lb (12 Nm) housing, reinstall it before attaching the rope handle.
1204331 Recoil Assembly: 14 ft-lb (19 Nm) 9. Slide the reel down the center shaft and into the
housing making sure the recoil spring re-engages the
reel tab.
CAUTION
10. Install the return spring and ratchet into the reel face.
The return spring leg fits in the notch on the ratchet
Recoil spring under high tension. Wear eye protection.
and holds the ratchet in (retracted).
1. Remove recoil housing from the engine. Un-tie knot in 11. Install friction spring with one leg inserted in the
the recoil rope and allow the reel to slowly unwind. bottom hole on the ratchet.
2. Remove the screw, washer, friction plate, ratchet 12. Apply Loctite 242 and install screw and washer
guide, friction spring, ratchet and return spring from and torque to specification.
the reel. 13. Pull rope out to its full extension and align pulley notch
3. Lift the reel straight out of the housing making sure the with rope hole in housing.
spring is no longer connected to the backside of the 14. Using a needle nose pliers or hooked wire, pull a loop
reel. of rope through the notch in the reel.
NOTE: If the recoil spring tension is removed, the 15. Prevent the rope from being retracted by tieing a knot
spring should stay inside the housing. in the rope on the outside of the housing at the rope
4. Inspect all components for signs of abnormal wear. guide hole.
Replace components as required. If replacing the
16. Wind the recoil pulley counterclockwise until the
rope, tie a small square knot at one end. Push the knot
spring begins to bind. Unwind the pulley clockwise two
firmly into the pocket on the reel.
revolutions.
5. If the reel recoil spring was removed during
17. Pull on the rope to disengage it from the notch in the
disassembly, install the spring by spiraling the spring
pulley. Un-tie the knot in the rope and allow it to retract
counterclockwise toward the center of the housing.
into the housing.
6. Lubricate the center shaft and spring with Premium
18. Pull on the handle to verify proper operation.

3.21
ENGINE COMPONENT ASSEMBLIES
600 Cylinder Head/Cylinders/Pistons
C
A
BLEED SCREW
B
THERMOSTAT COVER
HEAD COVER O-RINGS
THERMOSTAT
O-RINGS
GASKET
F
KNOCK SENSOR
E CYLINDERS
TEMP. SENSOR
D
BASE GASKETS
CYLINDER HEAD
PISTON RINGS
PISTON
BEARING
PISTON PIN
C-CLIP
Piston Matrix
=T
Engine Model Piston PN Piston ID
A: 70 in-lb (8 Nm) S4316-6044-OL6G
B: 9 ft-lb (12 Nm) - Apply Loctite 242 2204659 3226
S4452-6044-OL6G
C: 25 ft-lb (34 Nm) - Apply Loctite 242
D: 18 ft-lb (24 Nm) - Apply Pipe Sealant
E: 168 in-lb (19 Nm) - Clean and Dry
(DO NOT UNDER/OVER TORQUE SCREW.)
F: 37 ft-lb (50 Nm)
Piston Matrix
Engine Model Piston PN Piston ID
S4202-6044-OP6N
S4215-6044-OO6N 2204152 3222
S4357-6044-OL6N

Disassembly / Assembly Process
1. Remove the coolant from the engine using a siphon,

wet/dry vac, or drain pan.
2. Remove the oil tank/clutch cover, air box assembly,
and exhaust pipe from the engine compartment.
3. Remove the high tension wires and spark plugs from
the cylinder head.
4. Remove the thermostat housing outlet cooling hose
from the housing.
5. Loosen all, then remove all head cover fasteners.
3
Clean the fastener threads to remove any thread
locking residue.
6. Discard the head cover and cylinder head o-rings.
Always use new o-rings during assembly.
7. Inspect the cylinder head / combustion domes for any
damage. Measure cylinder head flatness. Replace
cylinder head if required.
8. If only the cylinder(s) are going to be removed,
remove the fuel rail from the upper fuel injectors.
9. Loosen all, then remove the cylinder base nuts.
10. Carefully pull each cylinder upwards taking care not
to drop the piston and rod abruptly against the
crankcase.
11. Remove the cylinder base gaskets. Use a gasket
scraper to clean the gasket residue from the
crankcase and cylinder bases.
12. Inspect the cylinder walls. Nicasil cylinders can only
be lightly honed. Damage that cannot be removed
with a light hone requires cylinder replacement or re-
chroming.
13. The assembly process is the reverse of disassembly.
14. Always use new gaskets and o-rings during
assembly. Liberally coat the inside of each cylinder
and the outside of each piston with Polaris two-stroke
engine oil.
15. Always refresh the cylinder crosshatch pattern using
a 320 grit stone. See Cylinder Honing on page 3.14.
16. When installing a piston into a cylinder, verify each
piston ring opening is located at each piston ring
locating pin. Squeeze the top ring, then carefully slide
the cylinder over the compressed ring. Do the same
with the bottom ring.
17. Follow the torque specifications and torque
sequences located at beginning of chapter when
tightening fasteners.

3.23
600/800 Recoil/Stator Assembly
TRIGGER COILS
FLYWHEEL NUT
STATOR
D
C
FLYWHEEL
HUB
A
RECOIL HOUSING
=T
A: 9 ft-lb (12 Nm)
B: 5 ft-lb (7 Nm) (Trigger coil fasteners)
C: 90 ft-lb (122 Nm) - Apply Loctite 242 (Do not
use an impact wrench to remove or install flywheel
nut.)
D: 12 ft-lb (16 Nm) - Apply Loctite 242

1. Remove the exhaust pipe and silencer.

2. If the recoil assembly does not require attention, the
recoil rope can remain attached to the handle. If recoil
component work is desired, reference the Recoil
Assembly section.
3. Remove the two mag-side engine mounting bolts.
Carefully lift the mag-side of the engine to access the
housing cover.
4. Remove the recoil/magneto housing cover. The recoil 3
assembly is located inside the housing.
5. Remove the recoil hub from the flywheel. Secure the
flywheel with a strap wrench, PN PU-45419. Remove
the flywheel nut and washer.
6. Using the flywheel puller tool, PN 2871043, insert the
pullers three screws into the flywheel.
NOTE: Do not thread the puller screws into the

magneto/stator located behind the flywheel.
7. Turn the puller center bolt in until the flywheel pops

off of the crankshaft.
8. Mark the location of the magneto/stator plate in
several places using a scribe.
9. Remove the two plastic rivets that prevent the trigger
coil wires from contacting the flywheel.
10. Remove the magneto/stator from the crankcase.
11. During assembly, route the trigger coil wires in their
designated channels. Install the two plastic rivets into
the housing to prevent the wires from accidently
coming into contact with the flywheel.
12. Assembly is reverse of disassembly. Reference the
fastener torque specifications at the beginning of the
chapter.
13. Do not use an impact wrench to install the flywheel
nut.
14. Align the mag-side engine mount with the two chassis
mounts. Install the engine mount screws and torque
to specification.
15. Reinstall the exhaust silencer and pipe.

3.25
600 Crankcase/Crankshaft Assembly
GEAR CLAMPS
A CYLINDER STUDS
INTAKE BOOT
REED STUFFERS ALIGNMENT DOWELS

REED BLOCKS
TRIGGER COIL WIRE RETAINER
OIL INJECTION CHECK VALVE QTY. 5
PTO SEAL
NEEDLE BEARINGS
FLYWHEEL KEY
PTO BEARINGS
MAG BEARING
CRANKSHAFT
MAG SEAL
TRIGGER COIL WIRE RETAINER
DO NOT FILL MAG

STATOR WIRE HARNESS RETAINER BEARING OIL
GALLERY WITH CASE
C SEALANT
= In. / mm.
Long Stud Height (Exhaust side): 4.13" (105mm)

Small Stud Height (Intake side): 2.16" (55mm)
=T
A: 9 ft-lb (12 Nm)
B: 22 ft-lb (30 Nm)
C: 10 ft-lb (13 Nm) - Apply Pipe Sealant

Disassembly / Assembly Process NOTE: Do not over-apply sealant in oil injector area.
Doing so may block the oil passage.
1. Remove the engine from the engine compartment. DOWELS
2. Follow the process for removing the cylinder head,
cylinders, pistons, flywheel / recoil housing, and the
water / oil pump.
3. Remove the intake boots, reed stuffers, and reed
assemblies from the intake tracks. Discard any seals
or gaskets.
NOTE: The crankcase ring land damage shown in the

corresponding photo is caused by improper
3
crankcase separation or crankshaft removal.
DO NOT FILL MAG

BEARING OIL
GALLERY WITH
CASE SEALANT
11. Loosely install the crankcase fasteners, then torque to

the specifications at the beginning of the chapter. Use
the correct torque sequence when tightening the
screws.
12. Liberally coat the crankshaft bearings and
components with Polaris two-stroke engine oil.
4. Remove all crankcase fasteners except ones marked

5-6-7-8 indicated below. Loosen these 4 bolts to
reveal about a 1/6"-1/8" bolt gap.
5. Once loosened, carefully and lightly tap on the bolts

to separate the crankcase halves.
6. Discard the PTO and MAG crankshaft seals.
7. Remove the crankshaft by pulling it straight up and
out. Inspect as required.
8. Thoroughly clean the two crankcase mating surfaces
with carburetor cleaner and a gasket remover. Flush
out the crankcase galleries.
9. Reinstall the crankshaft back into the lower crankcase
using two new crankcase seals. Verify the two
crankcase dowels are installed in the lower
crankcase.
10. Apply a thin bead of Three Bond 1217H to the lower
crankcase mating surface. Install the upper
crankcase.

3.27
800 DC-CFI-2 Cylinder Head/Cylinder/
Pistons
A BLEED SCREW
B
THERMOSTAT COVER
THERMOSTAT
GASKET
SPARK PLUGS
HEAD COVER
TEMP. SENSOR CYLINDER

O-RINGS
D
THROTTLE BODY HOSE
CYLINDER HEAD
PLUG* BASE GASKET
BYPASS NOZZLE*
O-RINGS
KNOCK SENSOR E
PISTON RINGS
PISTON PIN
PISTON
C-CLIP
* = SEE PLUG / BYPASS MATRIX
=T
A: 70 in-lb (8 Nm)
B: 9 ft-lb (12 Nm) - Apply Loctite 242
C: 25 ft-lb (34 Nm) - Apply Loctite 242
D: 18 ft-lb (24 Nm) - Apply Pipe Sealant
E: 168 in-lb (19 Nm) - Clean and Dry
(DO NOT OVER/UNDER TORQUE SCREW.)
F: 42 ft-lb (57 Nm)

Cylinder Head/Cylinder/Piston Notes NOTE: Leave the exhaust Y-pipe attached to the
cylinder assembly. Remove Y-pipe after removing
Piston Matrix cylinder from crankcase.
Engine Model Piston PN Piston ID 9. Loosen all, then remove the cylinder bolts. Clean the
S4139-8044-OO8G bolt threads to remove any thread locking residue.
S4229-8044-OO8G 10. Carefully pull the cylinder upwards taking care not to
S4092-8044-OO8G drop the pistons and rods abruptly against the
2204322 3305 or 3335
S4360-8044-OL8G crankcase.
S4361-8044-OL8G
S4359-8044-OL8G
11. Remove the cylinder base gasket. Use a gasket
scraper to clean the gasket residue from the 3
crankcase and cylinder base.
800 pistons feature two different rings thicknesses. The 12. Inspect the cylinder walls. Nicasil cylinders can only
upper ring is 1.8mm thick, while the lower ring is 1.5mm be lightly honed using a 320 grit stone. Damage that
thick. cannot be removed with a light hone requires cylinder
replacement or re-chroming.
Some 800 DC-CFI-2 engines feature a coolant bypass
13. Inspect the crankcase and cylinder mating surfaces
nozzle on the cylinder head. Reference table below.
for warping.
Plug / Bypass Matrix 14. The assembly process is the reverse of disassembly.
15. Always use new gaskets and o-rings during
Cylinder Head Cylinder Head assembly. Liberally coat the inside of each cylinder
Engine Model
Plug Bypass Nozzle bore and the outside of each piston with Polaris two-
S4139-8044-OO8G stroke engine oil.
S4229-8044-OO8G 16. Always refresh the cylinder crosshatch pattern using
X
S4360-8044-OL8G a 320 grit stone. See Cylinder Honing on page 3.14.
S4361-8044-OL8G 17. When installing a piston into a cylinder, verify each
S4092-8044-OO8G piston ring opening is located at each piston ring
X locating pin. Squeeze the top ring, then carefully slide
S4359-8044-OL8G
the cylinder over the compressed ring. Do the same
with the bottom ring.
800 DC-CFI-2 Cylinder Head/Cylinder/
Pistons Disassembly/Assembly 18. Follow the torque specifications and torque
sequences located at beginning of chapter when
1. Remove the coolant from the engine using a siphon, tightening fasteners.
wet/dry vac, or drain pan.
2. Remove the air box, exhaust pipe and resonator from
the engine compartment.
3. Remove the high tension wires and spark plugs from
the cylinder head.
4. Remove the thermostat housing outlet cooling hose
from the housing.
5. Loosen all, then remove all head cover fasteners.
Clean the fastener threads to remove any thread
locking residue.
6. Discard the head cover and cylinder head o-rings.
Always use new o-rings during assembly.
7. Inspect the cylinder head / combustion domes for any
damage. Measure cylinder head flatness. Replace
cylinder head if required.
8. Remove the fuel rail and fuel injectors from cylinder.
See Fuel Rail/Injector Removal and Installation on
page 4.24.

3.29
800 DC-CFI-2 Crankcase/Crankshaft
GEAR CLAMPS
A REED STUFFERS
ALIGNMENT DOWELS
ADAPTER PLATE
SEAL GUARD
PTO SEAL
REED BLOCKS
STATOR WIRE RETAINER
OIL INJECTION CHECK VALVE QTY. 5

WRIST PIN BEARINGS
PTO BEARING
FLYWHEEL KEY
MAG BEARING
MAG SEAL
STATOR WIRE RETAINER
=T
A: 9 ft-lb (12 Nm)
B: 22 ft-lb (30 Nm) - Apply Loctite 242
C: 10 ft-lb (13 Nm) - Apply Pipe Sealant

Disassembly and Assembly Process - Crankcase/ NOTE: Do not over-apply sealant in oil injector area.
Crankshaft Doing so may block the oil passage.
DOWELS
1. Remove the engine from the engine compartment.
2. Follow the process for removing the cylinder head,
cylinders, pistons, flywheel/recoil housing, and the
water/oil pump.
NOTE: The crankcase ring land damage shown in the

corresponding photo is caused by improper
crankcase separation or crankshaft removal. 3
DO NOT FILL MAG

BEARING OIL
GALLERY WITH
CASE SEALANT
10. Loosely install the crankcase fasteners, then torque to

the specifications at the beginning of the chapter. Use
the correct torque sequence when tightening the
screws.
11. Liberally coat the crankshaft bearings and
3. Remove all crankcase fasteners except ones marked components with Polaris two-stroke engine oil.
5-6-7-8 indicated below. Loosen these 4 bolts to
reveal about a 1/6"-1/8" bolt gap. 800 DC-CFI-2 Crankshaft Identification
Two different crankshaft assemblies (Type 1 and Type 2)
are used for production and service parts. Use the codes
etched into the nose of the PTO end to determine
crankshaft type when ordering service parts.
Type 1 will have the number 3753. Type 2 will have the
number 0262.
4. Once loosened, carefully and lightly tap on the bolts
to separate the crankcase halves.
5. Discard the PTO and MAG crankshaft seals.
6. Remove the crankshaft by pulling it straight up and
out. Inspect as required.
7. Thoroughly clean the two crankcase mating surfaces
with carburetor cleaner and a gasket remover. Flush
out the crankcase galleries.
8. Reinstall the crankshaft back into the lower crankcase
using two new crankcase seals.
9. Apply a thin bead of Three Bond 1217H to the lower
crankcase mating surface. Install the upper
crankcase.

3.31
600/800 DC-CFI Water and Oil Pump
Assembly
SEAL
BEARING
A
WASHER CROSS SHAFT

OIL PUMP
WASHER
MECHANICAL SEAL
WASHER
IMPELLER
WASTER PUMP COVER GASKET
O-RING
A
NUT
C
WASTER PUMP COVER
B
=T
A: 10 ft-lb (13 Nm)
B: 9 ft-lb (12 Nm)
C: 18 ft-lb (Nm) Apply pipe sealant.

IMPORTANT: Use the mechanical seal installation

tool to install the water pump seal, PN: 2872010.
1. Remove the coolant from the engine using a siphon,

wet/dry vac. or a drain pan.
2. Remove the oil tank/clutch cover assembly, airbox,
exhaust pipe and resonator. Remove the hoses
connected to the water pump cover.
3. To access the impeller and mechanical seal, remove 3
the water pump cover. Discard the water pump cover
gasket.
4. Remove the impeller nut, impeller and washers from
the cross shaft.
5. Carefully pry the mechanical seal and seal out of the
crankcase.
6. Water pump assembly is the reverse of disassembly.
Always use new seals and gaskets during assembly.
7. To remove the oil pump, the engine must be removed
from the engine compartment. Remove the two
fasteners then pull the pump out of the crankcase
bore. Discard the o-ring.
8. The cross shaft can be extracted from the water pump
side of the crankcase.
9. Assembly is the reverse of disassembly. Always use
new o-rings, seals and gaskets during assembly.
10. Install a new seal onto the shaft from the water pump
side.
11. To install a new water pump seal, use the seal
installation tool, PN 2872010. Verify the seal lips are
facing the cross shaft gear.

3.33
Oil Hose Routing
TEE FITTING

Engine Removal 5. If the snowmobile is equipped with electric start,
disconnect the battery. Remove the starter motor from
NOTE: Inspect all parts for wear or damage during the motor bracket. Remove the worm drive shaft from
disassembly. Replace all seals, o-rings, and gaskets the case-mounted drive gear.
with Genuine Pure Polaris parts during assembly.
Torx screws are used throughout the engine MOUNTING NUT

compartment. Always use good-quality Torx
wrenches when removing or installing these screws.
STARTER MOTOR
Do not use worn or damaged tools.
1. Remove the left and right door panels. Remove the

3
hood assembly. MOUNTING NUT
2. Remove the drive belt, fender screw, drive clutch, and (+) CABLE
driven clutch.
CAUTION
Remove the RED (+) battery cable first, and then the
BLACK (-) cable last. Reverse order when attaching
cables to battery.
6. Remove the two screws securing the lower steering

FENDER SCREW shaft bushing clamp shaft to the over structure.
3. Remove the oil tank/clutch cover assembly.See Oil

Tank/Clutch Cover Service on page 2.14.
4. Remove the exhaust pipe, and exhaust silencer.
NOTE: Disconnect the exhaust temperature sensor

probe wiring harness. Do not remove probe from pipe
unless service is required.

3.35
7. Remove the upper steering drag link from the lower 12. Remove the coolant return hoses from the water
steering shaft. pump cover.
8. Remove the airbox assembly.See Air Box Servicing 13. Disconnect the throttle cable from the throttle body.
on page 2.23. 14. Cut the knot at the end of the recoil rope to remove
9. Remove the fuel supply and return hoses between the the handle. Pass the recoil rope through the console
fuel tank and fuel rail mounted to the engine. and guide. Tie the recoil rope in a knot to prevent it
10. Remove the surge tank cap. Extract the engine from retracting into the recoil housing.
coolant with a siphon or wet/dry vacuum. 15. Disconnect the engine torque link by removing the two
11. Remove the thermostat bypass and main outlet hoses screws securing the bracket to the bulk, and then the
from the thermostat housing. torque link lock nut.
NUT ON BACKSIDE

16. Remove the exhaust y-pipe from the engine using a 19. Remove the two engine mount screws from the MAG-
ball-end Allen wrench. Remove the exhaust gaskets. side of the engine.
If un-damaged, they can be re-used during assembly.
NOTE: Use a six to eight inch extended Allen wrench
to access the MAG-side engine mounting bolts.
17. Remove the PTO and MAG exhaust valve assemblies

from the cylinder. Doing this will provide clearance
between the engine and bulkhead so the engine can
be removed from the PTO-side of the engine 20. With the help of an assistant carefully remove the
compartment. engine from the PTO-side of the engine compartment.
18. Remove the two engine mounting screws from the 21. Use care when lifting the engine up and over the
PTO-side of the engine. tunnel and side support plate. Do not damage the oil
pump when pulling the engine out.

3.37
Engine Installation 12. Reinstall the exhaust gaskets and y-pipe. Torque y-
pipe fasteners to specification.
1. Clean the engine compartment.
2. Inspect engine mounts for damage. Replace mounts
or radial inserts at this time. If any mount bracket was
=T
removed, reinstall and torque screws to specification.
Exhaust Y-Pipe Screws: 22 ft-lb (30 Nm)
=T 13. Reinstall the throttle cable. Verify the throttle cable

freeplay is set to specification.
Engine Mount Bracket: 22 ft-lb (30 Nm) 14. Install the MAG and PTO exhaust valve assemblies
using new gaskets. Torque fasteners to specification.
3. Verify cooling hose and starter motor power cable Reconnect vent hoses and secure clamps.
(electric start models) are secured to the bulkhead
floor with a p-clamp. FASTENERS
NOTE: White tape on wire harnesses and hoses

designates clamp/harness retainer location.
4. Visually inspect the oil pump setting. If adjustment is

required, adjust the oil pump before installing the EV ASSEMBLY
engine. GASKET
5. With the help of an assistant of engine hoist, lower the

engine into the bulkhead.
6. Spray the radial inserts on each of the four engine
mounts with rubber lubricant or isopropyl alcohol. =T
Lubricating the radial inserts will prevent the engine
fasteners from catching on the rubber when they are
Exhaust Valve Mounting Screws: 2 ft-lb (16 Nm)
torqued.
Apply Loctite 242
7. Install all four engine mount screws by hand. Once all
four are installed, torque screws to specification. 15. Reinstall the lower steering shaft bushing bracket on
to the over structure by loosely installing the two
=T screws. Torque fasteners to specification.
Engine Mount Screws: See Page 3.20.
8. Install the torque link adjuster using a new lock nut.

Torque lock nut and screws to specification.
=T
Torque Link Nut/Screws: 26 ft-lb (35 Nm)
9. Reinstall the surge tank-to-water pump and heat

exchanger-to-water pump hoses on to the water
pump cover.
10. Reinstall the coolant outlet and bypass outlet hoses
at the thermostat housing. Open the bleed slightly to
allow air to escape when the engine is filled with
coolant. =T
11. If the snowmobile is equipped with electric start,
reinstall the starter worm drive shaft, and the starter Lower Steering Shaft Bushing Bracket:
motor. 15 ft-lb (20 Nm)

16. Reinstall the steering drag link with the rod ends NOTE: Install the silencer mount rubber dampener
parallel to each mating surface. Torque nuts to with the fat end facing outwards.
specification.
=T
Steering Drag Link Rod End Nuts: 37 ft-lb (50 Nm) SILENCER MOUNT
17. If the snowmobile is equipped with electric start,

reinstall the battery and reconnect the battery cables.
Connect BLACK negative (-) cable first, and then RED 3
positive (+) cable last.
CAUTION
Attach the BLACK (-) battery cable first, and then the
RED (+) cable last.
18. Reinstall the exhaust silencer. Verify the silencer

outlet tube is installed in the fender boot and that the
boot has not been pushed out of the fender.
19. Torque the silencer rubber mount fastener to
specification.
=T
Silencer Mount: 17 ft-lb (23 Nm)
20. Reinstall the exhaust pipe. Verify the gray springs are
installed at the pipe-to-manifold locations.
21. Reconnect the over structure electrical component
wire harness connections. Verify the white harness
bands are routed so they can be fitted into each
respective harness retainers.
22. Clean the PTO clutch taper with emery cloth. Reinstall
the drive clutch. Torque fastener to specification.
=T
Drive Clutch Bolt Torque: 80 ft-lb (108 Nm)

3.39
23. Reinstall the driven clutch assembly. Torque fastener
to specification.
=T
Driven Clutch Bolt Torque: 18 ft-lb (25 Nm)
24. Reinstall the drive belt.

25. Reinstall the airbox assembly. See Air Box Servicing
on page 2.23.
26. Reinstall the clutch cover/oil tank assembly. See Oil
Tank/Clutch Cover Service on page 2.14.
27. Fill the coolant surge tank with 60/40 Polaris engine
coolant. Follow the Cooling System Fill/Bleed
Procedure outlined in Chapter Two. See Cooling
System Bleeding on page 2.10.
28. Reinstall the hood assembly. See Door/Hood
Removal and Installation on page 2.24.
29. Reinstall the left and right door panels.
30. If the engine was rebuilt, follow the engine break-in
procedure. See Engine Break-In Procedure on
page 2.6.

COOLING SYSTEM 5. Verify the bleed screw and washer are installed.
Thermostat Replacement Thermostat Orientation

The thermostat must be installed in the cylinder head has
BLEED SCREW
shown in the illustrations.
WASHER
Center Thermostat Location
BRIDGE ALIGNED WITH HOLES

3
HOUSING COVER
Offset Thermostat Location
THERMOSTAT
GASKET
CAUTION 800 Thermostats

There are two different thermostats used depending on
Allow engine to cool completely before working with the what model the engine is installed in.
engine cooling system.
Engine coolant can be under pressure and hot. Cooling System Type Thermostat PN Bleed Hole ID
Escaping steam and/or coolant may cause severe
burns to exposed skin. RUSH/Switchback 7052433 2 mm
SB Assault/RMK
1. Remove the housing cover, by removing the cover PRO RMK/ 7052452 3.5 mm
bolts. RMK Assault
2. Check the gasket condition and replace if damaged.
3. Replace the thermostat. Make sure that the spring Both thermostats are full open at 120 F (49 C).
side is facing downward or toward the engine.
4. Replace cover. Torque the cover fasteners to
specification.
=T
Cover Fasteners: 9 ft-lb (12 Nm)

3.41
2010 600 RUSH Cooling System
SURGE BOTTLE
HOSE (BYPASS-TO-SURGE TANK)
REAR TUNNEL COOLER
HOSE (THROTTLE BODY-TO-SURGE TANK)
HOSE (SURGE TANK-TO-WATER PUMP)
FRONT TUNNEL COOLER
HOSE (TEE-TO-HEAT EXCHANGER)
WATER PUMP COVER
BARBED NOZZLE
HEAT EXCHANGER
BYPASS CIRCUIT ONLY ACTIVE WHEN THERMOSTAT IS CLOSED

FRONT EXCHANGER, FRONT TUNNEL COOLER, AND REAR TUNNEL COOLER CIRCUITS ACTIVE WHEN THERMOSTAT IS OPEN
NOTE: When the thermostat is closed, engine

coolant is bypassed back to the surge bottle.
When the thermostat is open, the bypass circuit is

closed. Engine coolant is routed to the front heat
exchanger, front tunnel cooler, and rear tunnel cooler.
Thermostat opening temperature is 120 F (49 C).

MID FLAP COOLER
SURGE BOTTLE
REAR TUNNEL COOLER

FRONT TUNNEL COOLER
WATER PUMP COVER
BARBED NOZZLE
HEAT EXCHANGER



exchanger, front tunnel cooler, tunnel cooler, and
mid-flap coolers.

3.43
MID FLAP COOLER
SURGE BOTTLE
REAR TUNNEL COOLER
FRONT TUNNEL COOLER
HOSE (THERMOSTAT OUTLET-TO REAR COOLERS)
HOSE (CYLINDER BYPASS

-TO-HEAT EXCHANGER)
WATER PUMP COVER
BARBED NOZZLE
HEAT EXCHANGER
NOTE: Front heat exchanger circuit always active.

Front tunnel cooler, tunnel cooler, and mid-flap cooler
only active when thermostat is open.
Models feature 2mm thermostat bleed hole.

2012 600 RUSH/Switchback Cooling System
MID FLAP COOLER

SURGE BOTTLE
WEAR STRIPCOOLERS
FRONT TUNNEL COOLER
WATER PUMP COVER
BARBED NOZZLE
HEAT EXCHANGER



exchanger, front tunnel cooler, tunnel coolers, and
mid-flap coolers.

3.45
2012 800 RUSH/Switchback Cooling System
MID FLAP COOLER

SURGE BOTTLE
REAR TUNNEL COOLER
FRONT TUNNEL COOLER
HOSE (CYLINDER BYPASS

-TO-HEAT EXCHANGER)
WATER PUMP COVER
BARBED NOZZLE
HEAT EXCHANGER
NOTE: Front heat exchanger circuit always active.

Front tunnel cooler, tunnel cooler, and mid-flap cooler
only active when thermostat is open.
Models feature 2mm thermostat bleed hole.

Pro-Ride Switchback Assault/RMK Cooling System
HOSE (FRONT COOLER

TO-SURGE TANK)
SURGE BOTTLE
HOSE (THROTTLE BODY
3
-TO-SURGE TANK)
REAR TUNNEL COOLER
HOSE (SURGE TANK

-TO-WATER PUMP)
HOSE (HEAD BYPASS-TO

FRONT TUNNEL COOLER)
NOTE: Front tunnel cooler circuit always active. Rear

tunnel coolers only active when thermostat is open.
Models feature 3.5mm thermostat bleed hole.

3.47
Pro-Ride PRO RMK/RMK Assault Cooling System
SURGE BOTTLE
HOSE (THERMOSTAT OUT-TO-TUNNEL COOLERS)
NOTE: Models feature 3.5mm thermostat bleed hole.

Cylinder head outlet plugged.

Front Heat Exchanger Service 8. Remove the bottom heat exchanger fastener.

hood assembly.
2. Remove the exhaust pipe.
3. Drill out and remove the rivets that attach the air dam BOTTOM FASTENER
plate to the bulkhead, and the two rivets that attach

the nosepan to the plate.
4. Remove the screw attaching the bumper to the heat
3
exchanger. Loosen the two rear bumper screws.
LOOSEN REAR SCREWS
9. Pinch-off the coolant in and out hoses using dedicated

hose pinchers or soft-jawed pliers.
10. Remove the two heat exchanger hose clamps.
Remove the heat exchanger from the bulkhead.
11. Reverse the disassembly process to install the heat
REMOVE THIS SCREW exchanger and bumper.
12. Add engine coolant to the surge bottle. Bleed the
cooling system. See Cooling System Bleeding on
5. Drill out the rivets that attach the bumper to the
page 2.10.
nosepan.
6. Rotate the bumper up and away from the nosepan.
7. Locate the lower exchanger fastener.
AIR DAM PLATE
NOSE PAN

3.49
EXHAUST SYSTEMS
PRO-RIDE DC-CFI-4 Exhaust System
HEAT SHIELD
ZINC-PLATED (YELLOW) SPRINGS
HEAT SHIELD
MOUNT BUMPER
(INSTALL LARGE END TO OUTSIDE)
C
GASKET EXHAUST SEAL
EXHAUST PIPE
D
GASKETS
STAINLESS STEEL (GRAY) SPRINGS
When removing the exhaust pipe, disconnect the EGT

=T probe wire harness. Do not remove the EGT probe
from the pipe if not necessary.
A: EGT Sensor: 32 ft-lb (44 Nm) Apply anti-seize to
threads.
B: Exhaust Manifold Fasteners: 22 ft-lb (30 Nm)
C: Silencer Rubber Mount Fastener = 17 ft-lb (23 Nm)
D: Silencer Bracket Fasteners = 26 ft-lb (35 Nm)
NOTE: Always use the stainless steel (gray) springs

to connect the exhaust pipe to the exhaust manifold.

PRO-RIDE DC-CFI-2 Exhaust System
ISOLATOR
GASKET
CHASSIS GROMMET
GASKET
EXHAUST PIPE
EXHAUST SEAL
B
STAINLESS STEEL (GRAY) SPRINGS
=T
A: EGT Sensor: 32 ft-lb (44 Nm) Apply anti-seize to
threads.
B: Exhaust Manifold Fasteners: 22 ft-lb (30 Nm)
NOTE: Always use the stainless steel (gray) springs

to connect the exhaust pipe to the exhaust manifold.
When removing the exhaust pipe, disconnect the EGT

probe wire harness. Do not remove the EGT probe
from the pipe if not necessary.

3.51
Variable Exhaust System (VES)-Threaded Valve
SPACER
CAP NUT
GUILLOTINE
EV CAP
B GASKET
A EV BASE
SPRING
BELLOWS
=T
EV Cap Screws (A): 10.5-13.5 ft-lb (14.3-18.3 Nm)
Apply Loctite 242 to cylinder screws.
Cap Nut (B): 14-18 ft-lb (19.1-24.5 Nm)
Apply Loctite 242 to threads.
Assembly Notes:
Replace spring if rusted, bent, or distorted

Inspect bellows for tears.
Inspect guillotine threads and cap nut threads for
wear/galling. Replace parts as required.
Discard gasket. Replace with new parts during
assembly.
Clean components as outlined in Chapter 2-
Maintenance.

Variable Exhaust System (VES)-Threaded Stud
BELLOWS
EV BASE
SPRING
3
GUILLOTINE
EV CAP CAP NUT
THREADED STUD/WASHER GASKET
soft-faced bench vise. Loosen cap nut.

=T
EV Cap Screws(A): 10.5-13.5 ft-lb (14.3-18.3 Nm)
Apply Loctite 242 to cylinder screws.
Cap Nut/Threaded Stud Asm.(B): 18-22 ft-lb
(24.5-29.9 Nm) Apply Loctite 242 to threaded
stud threads.
Assembly Notes:
Replace spring if rusted, bent, or distorted

Inspect bellows for tears.
Inspect threaded stud, cap, guillotine threads and If the complete assembly un-screws from the guillotine,
cap nut threads for wear/galling. Replace parts as use special tool PS-50753 to clamp the threaded stud/
required. washer in the bench vise.
Discard gasket. Replace with new parts during
assembly.
Clean components as outlined in Chapter 2-
Maintenance.
Special Tool:
VES Threaded Stud/Cap Tool
PS-50573
During reassembly, apply Loctite 242 to the threaded

stud/washer guillotine and cap nut threads. Loosely
Use special tool: PS-50753 to disassemble the cap nut, install the threaded stud/washer, bellows, and cap nut.
bellows and threaded stud/washer assembly. Torque only cap nut to specification to fasten all
components.
To disassemble guillotine components, clamp blade in
NOTE: A new threaded stud/washer has pre-applied
thread lock. No Loctite is required.

3.53
NOTES

Cleanfire Fuel Injection
CHAPTER 4
SERVICE WARNINGS AND PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
SERVICE WARNINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.2
ENGINE PROTECTION FEATURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
ENGINE TEMPERATURE RPM LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
ENGINE OVERHEATING TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.3
DETONATION PROTECTION (DET)/RPM LIMIT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
DET TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.4
CLEANFIRE FUEL INJECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
SYSTEM OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.5
4
DC-CFI-2/4 FUEL SELECT MODES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
DUAL RESISTOR FUEL SELECTOR PLUG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.6
DIAGNOSTIC TROUBLE CODES (DTCS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.7
DIAGNOSTIC TROUBLE CODE (DTC) TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . 4.9
INSTRUMENT CLUSTER CODE DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.9
ECU 34 PIN CONNECTOR (CHASSIS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.10
ECU 26 PIN CONNECTOR (ENGINE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.11
EXHAUST TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
TEMPERATURE / AIR PRESSURE SENSOR (TMAP) . . . . . . . . . . . . . . . . . . . . . . . . 4.12
CRANKSHAFT POSITION SENSORS (CPS) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
CRANKSHAFT POSITION SENSOR AIR GAPS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.12
EXHAUST VALVE SOLENOID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
IGNITION COILS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.13
ENGINE COOLANT TEMPERATURE SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
KNOCK (DET) SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
THROTTLE BODY REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.14
DC-CFI-4 FUEL INJECTORS/FUEL RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
FUEL INJECTORS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
FUEL RAIL BLEEDING / PRESSURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.15
DISCONNECT FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
FUEL RAIL/INJECTOR REMOVAL/INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . 4.16
FUEL SYSTEM ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.19
DC-CFI-2 FUEL INJECTORS/FUEL RAIL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20
FUEL INJECTORS/ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.20
FUEL RAIL BLEEDING / PRESSURE TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.21
DISCONNECT FITTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.22
FUEL RAIL MICRODAMPERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.22
FUEL RAIL/INJECTOR REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 4.23
FUEL TANK/PUMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24
2010 FUEL TANK/PUMP ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.24
2011-2012 RUSH/SWITCHBACK FUEL TANK/PUMP ASSEMBLY . . . . . . . . . . . . . . . 4.25
2011-2012 SWITCHBACK ASSAULT/RMK FUEL TANK/PUMP ASSEMBLY . . . . . . . 4.26
FUEL TANK SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27
FUEL PUMP SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.27
FUEL PUMP/LEVEL SENDER TEST SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . 4.28
FUEL TANK PRESSURE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.28
RUSH/SWITCHBACK FUEL PUMP PICKUP ORIENTATION . . . . . . . . . . . . . . . . . . . 4.29

4.1
DIGITAL WRENCH DIAGNOSTIC SOFTWARE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.30
DIGITAL WRENCH DIAGNOSTIC SOFTWARE OVERVIEW . . . . . . . . . . . . . . . . . . 4.30
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.30
DIAGNOSTIC SOFTWARE VERSION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.30
ECU REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.30
GUIDED DIAGNOSTICS AVAILABLE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.30
DIGITAL WRENCH COMMUNICATION ERRORS . . . . . . . . . . . . . . . . . . . . . . . . . . 4.31
DIGITAL WRENCH - DIAGNOSTIC / POWER CONNECTORS . . . . . . . . . . . . . . . . 4.31
DIGITAL WRENCH SERIAL NUMBER LOCATION . . . . . . . . . . . . . . . . . . . . . . . . . . 4.32
DIGITAL WRENCH VERSION AND UPDATE ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.32
DIGITAL WRENCH UPDATES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.32
DIGITAL WRENCH FEATURE MAP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.34
UPDATING DIGITAL WRENCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.35
VERSION IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.36
SPECIAL TESTS MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.36
VEHICLE HISTORY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.36
SERVICE REPORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.36
ECU REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.37
ENGINE CONTROLLER REPROGRAMMING (REFLASH) . . . . . . . . . . . . . . . . . . . . . 4.37
DIGITAL WRENCH DATA GRID SCREENSHOTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.40
THROTTLE POSITION SENSOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.41
THROTTLE POSITION SENSOR (TPS) OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . 4.41
TPS TESTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.42
TPS SET PROCEDURE MENU . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.43
VARIABLE EXHAUST SYSTEM (VES). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.47
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.47
ELECTRONIC REVERSE (PERC) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.48
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.48
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.48
FORWARD OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.48
ALTITUDE SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.49
IMPORTANT NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.49
TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.50
ENGINE WILL NOT START . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.50
ENGINE STARTS - WONT IDLE/STALLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.50
POOR PERFORMANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.50
DC-CFI TROUBLESHOOTING FLOWCHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4.51
DETONATION LIMIT TROUBLESHOOTING FLOWCHART . . . . . . . . . . . . . . . . . . . . . 4.52

SERVICE WARNINGS AND

PRECAUTIONS CAUTION
Service Warnings Never use fuel containing more than 10% ethanol or E85
fuels.
When servicing the fuel system, it is
important to heed the following warnings. All fuel injectors must share the same color code
(Yellow, Blue, or Red).
WARNING Always verify the fuel injector part number prior to
installation.
PROPOSITION 65 WARNING
Snowmobile engines discharge fuel and exhaust which
contain chemicals known to the State of California to
cause cancer and birth defects or other reproductive 4
harm, onto the snow on which they operate. Keep this
engine properly tuned and avoid unnecessary idling
and spillage during fueling.
Do not smoke or allow open flames or sparks in or near

the area where refueling is performed or where gasoline
is stored or used.
Do not overfill the tank past the bottom of the filler neck.
If you get gasoline in your eyes or if you swallow

gasoline, see your doctor immediately.
Never start the engine or let it run in an enclosed area.
Gasoline powered engine exhaust fumes are

poisonous and can cause loss of consciousness and
death in a short time.
If you spill gasoline on your skin or clothing,

immediately wash it off with soap and water and change
clothing.

4.3
ENGINE PROTECTION FEATURES Engine Overheating Troubleshooting
Engine Temperature RPM Limit If the hot lamp is illuminated or flashing with the engine
overheat RPM misfire enabled, reference the table below.
The ECU will illuminate the instrument cluster engine hot
LED when it determines the engine is overheating. The CAUSE OF OVERHEAT SOLUTION
ECU will flash the hot LED and enable a RPM misfire if it
determines continued engine operation will cause serious Ride snowmobile on good
engine damage. The ECU makes this determination Riding in poor conditions snow (loose, fresh, un-packed
based on current engine coolant temp, engine RPM, and snow)
throttle position. Allow engine to cool. Refill
Low coolant level coolant surge bottle to COLD
Engine Temperature Limit Modes line
Use 60/40 (propylene glycol/
HOT LAMP Incorrect coolant/mix ratio
MODEL THRESHOLD* distilled water mixture
MODE
Air in cooling system Bleed cooling system
Hot Lamp Illuminates:
Heat exchangers/hoses Inspect components for
Hot Lamp ON Idle = 230 F/110 C
damaged or plugged damage, hose kinks, etc.
WOT = 185 F/85 C
600/800 Inspect thermostat for proper
DC-CFI 2/4 Hot Lamp Flashes Thermostat malfunctioning
operation
Hot Lamp RPM Misfire at:
FLASH Idle = 239 F/115 C Water pump malfunctioning Inspect coolant flow
WOT = 208 F/98 C Pressure test cooling system.
Cylinder base gaskets/o-rings Verify system holds pressure/
NOTE: * = Only minimum (idle) and maximum (WOT) damaged. pressure does not leak into
parameters listed. cylinders
Inspect rear snow flap
Snow flap damaged or
The driver must take immediate action to cool the engine assembly. Verify flap(s) are not
removed
once the hot LED is illuminated. Drive the snowmobile in damaged or missing
loose, un-packed snow to cool the engine. If trail Verify vehicle is not overloaded
conditions are poor, turn the engine off and allow it to cool. during operation (high load/
Vehicle use
When the engine is cool, check the coolant level in the high engine RPM and low
ground speed)
surge bottle (reservoir). Only add coolant when the engine
is sufficiently cooled. Never add coolant when engine is Verify track is not missing lugs.
Track condition/tension
hot. Set correct track tension
If the snowmobile must be operated while the indicator

LED is illuminated, drive slowly and stop the engine
frequently to allow it to cool down.
Continued engine operation with the engine hot LED
illuminated may cause serious engine damage. If the ECU
determines serious engine damage may occur, the hot
lamp will flash and an engine RPM misfire will be enabled.
The ECU will also register and accumulate (count the
number of occurrences) DTCs (110/0 or 110/16) if the
engine overheats or goes into the overheat misfire mode.

Detonation Protection (DET)/RPM Limit NOTE: A DET Troubleshooting flowchart is located

at the end of the chapter.
When DET is sensing and taking action to reduce
detonation, the driver may notice a drop in engine RPM
CAUSE OF DET ACTIVATION SOLUTION
and/or reduced performance.
Refill tank with recommended
The ECU will illuminate the instrument cluster check Low fuel/no fuel in tank
fuel
engine LED and display dET on the LCD screen
whenever the DET system is active. Verify correct fuel selector
Incorrect ethanol/non-ethanol
resistor installed for fuel type in
If the ECU determines the detonation cannot be controlled fuel resistor installed
tank
by normal means and further operation may cause engine
Replace with higher quality
damage, the check engine LED will flash, the instrument
Poor quality fuel/water in fuel fuel. Recommended 91 octane
cluster will display dET, and the ECU will limit the
minimum
maximum engine speed to 6,500 RPM. The RPM limit will
remain active until the driver turns off and restarts the
Alcohol-based fuel additives
Do not use deicers or additives
that contain any form of alcohol
4
engine.
used with ethanol fuel when using ethanol-blended
fuel
Restricted fuel filter Replace fuel filter
Verify fuel pressure is 58 psi (4
Low fuel pressure
BAR) at idle and while riding
Verify fuel injection circuit is at
Low fuel injector voltage 16 VDC when engine is
running
Use Digital Wrench to
Faulty/plugged fuel injector
troubleshoot
Verify valves are not stuck
If the detonation RPM limit occurs, a diagnostic trouble VES system malfunctioning open, vent hoses are not
frozen or plugged
code (DTC) will be registered. Digital Wrench will display
one of the following codes: 1352/0 (P1336), 1352/16 Verify knock sensor screw
Knock sensor malfunctioning
(P2336), 1353/0 (P1337), or 1353/16 (P2337). torque is set to specification
Verify air intake system is
DET Protection RPM Limit Modes sealed. Check throttle body
Air leaks boots for cracks/tears/loose
CHECK ENGINE parts. Remove after-market air
MODEL LED/INSTRUMENT RPM LIMIT intake system.
CLUSTER MODE
Engine/exhaust modifications Remove modifications
Check engine Check cooling system. Ride
Driver may notice Engine coolant temperature
LED illuminated/ snowmobile on loose, un-
slight drop in engine high
dET displayed packed snow
RPM/power
600/800 on LCD Verify crankcase seals are
DC-CFI-2/4 Check engine good (not leaking). Verify
6,500 RPM Misfire Mechanical failure
LED flashing/ engine in good condition.
Turn off engine to Check spark plugs.
dET displayed
reset.
on LCD
DET Troubleshooting
If the check engine LED is illuminated and/or flashing with
dET displayed on the instrument cluster, reference the
following table.

4.5
CLEANFIRE FUEL INJECTION Exhaust Valve Solenoid: Activated by the ECU,

the solenoid controls the VES venting. When
System Overview powered, the solenoid is open allowing cylinder
pressure to vent, and the exhaust valves remain
System components include: closed (down). When power is removed, the
solenoid closes and the exhaust valves will lift.
ECU: The ECU controls the ignition / fuel injection
angle, chassis/battery relays, and supplies the Throttle Position Sensor (TPS): The TPS relays
MFD gauge with tachometer, water temperature, the position of the throttle plates (operator throttle
PERC, HOT, DET, and diagnostic information. input) to the ECU.
Coolant Temperature Sensor: Relays the engine
CAUTION temperature to the ECU.
Exhaust Temperature Sensor: Relays the
CFI and DC-CFI ECUs cannot be interchanged. Serious temperature of the exhaust pipe to the ECU.
engine damage may occur. Temperature / Manifold Air Pressure
(T-MAP) Sensor: Relays the current intake air
Stator: Stator lighting charge coil split into two temperature and ambient air pressure to the ECU.
independent circuits; one for DC power (Chassis) The sensor is located on the airbox.
and one for AC power (Lighting). Vehicle Speed Input: The ECU monitors the
Flywheel: Flywheel is forged. Fan cover is vehicle speed supplied by the vehicle speed
removed from flywheel. sensor.
CFI Regulator / Rectifier: Supplies power to the Fuel Pump: Supplies fuel to the fuel injectors.
ECU, fuel pump boost power, MFD, LED tail Power to the fuel pump is supplied by the
lamp, and accessory DC power points. regulator / rectifier.
Capacitor: The capacitor suppresses voltage Diagnostic Connector: The ECU can
spikes and ensures consistent voltage throughout communicate with the Polaris Digital Wrench
the DC-CFI (RED-RED/WHT) circuits. software and can be re-flashed, monitored and will
Chassis Relay: The chassis relay on DC-CFI display trouble codes.
models supplies power to the MFD gauge, AC Regulator/Battery Charge Rectifier: The
accessory plug and DC power test plug. head lamps and hand/thumb warmers are
Ignition Coils: Provide ignition energy to each powered by AC voltage. If snowmobile is
spark plug. Both coils are fired at the same time. equipped with electric start, the regulator/rectifier
Fuel Injectors (4 Injector): This system features supplies DCV to charge the battery.
a set of fuel injectors mounted to the crankcase,
and a set of fuel injectors mounted to the cylinders
(ports).
Fuel Injectors (2 Injector): This system features
a set of fuel injectors mounted to the cylinders
(ports).
Detonation Sensor: Located on the cylinder
head, the detonation sensor transforms internal
acoustic information into a signal the ECU uses to
determine the amount of engine knock.

DC-CFI-2/4 Fuel Select Modes <91/10% ETHANOL/24 OHM Resistor Plug

Part Number =2411280 (Installed at the factory.)
CAUTION
Lock Screw
Always verify the ETHANOL resistor plug is installed in
the selector plug if unsure of fuel type. Severe engine
damage may occur if the PREMIUM resistor plug is
installed when using ethanol-blended fuel.
Never use fuels containing more than a 10% ethanol

blend.
DC-CFI-2/4 models allow the operator to select between

91+ octane non-oxygenated fuels or <91 octane or
91+ NON-ETHANOL/160 OHM Resistor Plug
Part Number =2411282 (Included in tool kit.)
4
oxygenated fuels.
The fuel selector resistor plug is located on the main wiring
harness attached to the over structure behind the left-side Lock Screw
door panel
When using <91 octane, oxygenated, or when unsure of
the fuel type inside the fuel tank, plug the 10% ETHANOL/
24 OHM resistor into the fuel selector plug.
When using 91+ non-oxygenated fuels, install the NON-
ETHANOL/160 OHM resistor into the fuel selector plug.
FUEL RESISTOR PLUG
Dual Resistor Fuel Selector Plug
Lock Screw
2012 models are equipped with one fuel selector plug
featuring dual resistors. The part number for the plug is
2411631 and it can be used on all DC-CFI models.
OIL TANK

4.7
Diagnostic Trouble Codes (DTCs)
P-
TROUBLE CODE SPN FMI MIL DESCRIPTION
CODE
Throttle Position Sensor Abnormal Rate of

10 P0120 TPS signal changes too rapidly to be correct.
Change
51 ON
Throttle Position Sensor Voltage High 3 P0123 TPS signal is above 4.39 VDC.
Throttle Position Sensor Voltage Low 4 P0122 TPS signal is below 0.7 VDC.
Vehicle Speed Sensor 84 2 P0503 2010-ON Data erratic or intermittent (missing).
Oil level is low. Sensor disconnected or oil
Oil Level Switch 98 17 P250F
level fell below switch level.
Intake Air Temperature Circuit Voltage High 3 P0113 Sensor signal is above 4.9 VDC.
105
Intake Air Temperature Circuit Voltage Low 4 P0112 Sensor signal is below 0.19 VDC.
Barometric Pressure Sensor Voltage High 3 P2229 Sensor signal is above 3.23 VDC.
108
Barometric Pressure Sensor Voltage Low 4 P2228 Sensor signal is below 1.25 VDC.
Engine Coolant Temperature Sensor Voltage
3 P0118 Sensor signal is above 4.8 VDC.
High
Engine Coolant Temperature Sensor Voltage
4 P0117 Sensor signal is below 0.1 VDC.
Low
Code is set and occurrences accumulated
Coolant Temperature Too High 16 P0217 (counted) in ECU whenever engine
110 temperature hot lamp is illuminated.
ON Code is set and occurrences accumulated
Engine Overheat Shutdown (Misfire) 0 P1217 (counted) in ECU whenever ECU enables
engine overheat misfire mode.
Code is set and occurrences accumulated
Engine Temp. Above Normal 15 P1116 (counted) in ECU whenever ECU enables hot
lamp.
3 P1569 Chassis voltage too high.
Alternator Power Supply 167
4 P1568 Chassis voltage too low.
Sensor signal is above 4.9 VDC for at least 2
EGT Sensor Circuit Voltage High 3 P0546 minutes and the engine has been running at
or above 3000 RPM.
173
Sensor signal is below 0.06 VDC for at least
EGT Sensor Circuit Voltage Low 4 P0545 2 minutes and the engine has been running at
or above 3000 RPM.
ECU Memory 628 13 P0601 Checksum / CRC Error
8 P0336 Circuit fault.
Crankshaft Position Sensor 636 2010-ON
2 P0335 Plausibility fault.
OPEN circuit or short to ground. Can be
5 P0261 caused by faulty wiring, injector, stator or
Port MAG Injector Circuit 651 ON ECU.
3 P0262 Circuit shorted to battery voltage.

P-
TROUBLE CODE SPN FMI MIL DESCRIPTION
CODE

5 P0264 caused by faulty wiring, injector, stator or
Port PTO Injector Circuit 652 ECU.
Engine speed is above 6000 RPM and the
Detonation Sensor Circuit Voltage Low 731 4 P0327 sensor signal is above 4.3 VDC for at least 2
ON seconds.
Failure within the primary circuit. Can be
Ignition Coil Circuit Malfunction 1268 5 P1351
caused by faulty wiring, ignition coil, or ECU.
Fuel Pump Driver Circuit 1347 5 P0230 Drive circuit open or shorted to ground.
Maximum Detonation Correction Limit
4
0 P1336
Knock Level (MAG) 1352 Reached
16 P2336 2010-OFF Knock above critical level-Latch Mode
Maximum Detonation Correction Limit
0 P1337 ON
Knock Level (PTO) 1353 Reached
16 P2337 2010-OFF Knock above critical level-Latch Mode
TPS/TMAP Sensor Supply Voltage (5VDC) 3509 P06B1 ON
4 Voltage too low.
Ground Speed Sensor Supply Voltage (5VDC) 3510 P06B4 2010-ON
Fuel Injector ECU Output Supply Voltage 3 P16A9 Voltage too high.
3598
(16 VDC) 4 P16A8 Voltage too low.
3 P1555 ON Voltage too high.
Throttle Switch Signal 520194 4 P1554 Voltage too low.
7 P1552 Throttle is stuck.
Chassis relay driver circuit is OL or shorted to
Chassis Relay Circuit Open/Grounded 5 P1611
ground.
520208 2010-ON
Chassis relay drive circuit is shorted to
Chassis Relay Driver Shorted to Battery Voltage 3 P1614
battery voltage.
Solenoid control circuit is OPEN. Can be
5 P1477
Exhaust Valve Solenoid 520215 caused by faulty wiring, solenoid, or ECU.
Crankcase MAG Injector Circuit 5 P1261 caused by faulty wiring, injector, stator or
520216 ECU.
(600 DC-CFI-4 ONLY)
ON
Crankcase PTO Injector Circuit 5 P1264 caused by faulty wiring, injector, stator or
520217 ECU.
(600 DC-CFI-4 ONLY)
3 P0179 Voltage too high.
Fuel Type Selected 524007 4 P0178 Voltage too low.
2 P0177 Signal Out of Range

4.9
Diagnostic Trouble Code (DTC) Instrument Cluster Code Display

Troubleshooting
Active diagnostic trouble codes can be reviewed by
Always use the Digital Wrench diagnostic software accessing the instrument clusters diagnostic display
program to troubleshoot DTCs, and overall performance mode.
problems. The diagnostic display mode is accessible when a trouble
Digital Wrench can be used to display trouble codes and code is active (MIL illuminated) and when the engine is
offers guided diagnostics. Guided diagnostics allows the running.
technician to perform diagnostic checks to isolate the root 1. Set the parking brake.
problem.
2. With the engine running and the MIL illuminated,
1. To access trouble codes, click on the ! button. If press and release the SELECT button or SET switch
code(s) are listed, select a code to proceed. to toggle to the diagnostic display mode. When a code
is active, the diagnostic display mode will appear
immediately following the engine hour display.
NOTE: When the diagnostic mode is displayed, the

check engine MIL will flash and Err will be shown.
3. A set of two numbers will appear in the display.

The 2-6 digit suspect parameter number (SPN) in
the information display area indicates which
component is generating the fault code.
The 1-2 digit failure mode indicator (FMI) number
in the odometer area indicate the fault mode, such
as open or short circuit.
2. Select a code or system in the SYSTEM CHARTS

menu. A description of the DTC or system will be
displayed.
A
SPN =
FMI =
4. More than one fault may be active. Press and hold the
MODE button or MODE switch for two seconds to
toggle to the next active code. Repeat until all codes
3. Click on (A) to activate guided diagnostics. are retrieved.
4. Click on X to exit the current screen.
NOTE: SPN= and FMI= are not displayed on
screen.

ECU 34 Pin Connector (Chassis)
NOTE: Wire Entry View

4
PIN COLOR GOES TO CONNECTOR FUNCTION
1 DG/WHT IGNITION SWITCH STARTER LOCKOUT
3 RD/BLK ELECTRIC START BATTERY VOLTAGE
7 BLK/DB SENSOR GROUND SPLICE SENSOR GROUND
8 DG/RD GROUND SPEED SPLICE GROUND SPEED SIGNAL
9 BLACK IGNITION SWITCH HARD STOP SWITCH
10 GRAY LH CONTROL SIGNAL PLUG PERC SWITCH
11 OG/BLK BRAKE SWITCH BRAKE SWITCH SIGNAL
12 VIOLET OIL LEVEL SWITCH LOW OIL SWITCH
14 PK/BLK FUEL MODE PLUG FUEL QUALITY SWITCH
15 BROWN
ECU GROUND SPLICE ECU GROUND
16 BROWN
17 ORANGE EXTERNAL POWER SPLICE EXTERNAL POWER
19 BN/YEL FUEL PUMP PRIME GROUND SPLICE FUEL PUMP ON/OFF CONTROL
20 ORANGE
VOLTAGE BOOST FUEL INJECTION VOLTAGE BOOST
21 ORANGE
25 BK/RED THROTTLE SAFETY SWITCH THROTTLE SOFT STOP
26 OG/WHT SPEED SENSOR CAPACITOR SPEED SENSOR POWER
27 DARK GREEN CAN LOW CAN LOW SIGNAL
28 YELLOW CAN HIGH CAN HIGH SIGNAL
30 WHT/YEL EV SOLENOID SOLENOID ON/OFF CONTROL
33 WHT/DB CHASSIS POWER RELAY RELAY COIL ON/OFF CONTROL
34 RED REGULATOR POWER SPLICE DC REGULATED VOLTAGE

4.11
ECU 26 Pin Connector (Engine)
NOTE: Wire Entry View
PIN COLOR GOES TO CONNECTOR FUNCTION
PTO CRANKCASE INJECTOR DRIVER

1 DARK BLUE
(DC-CFI-4)
FUEL INJECTOR HARNESS PLUG
2 DARK BLUE/WHT PTO CYLINDER INJECTOR DRIVER
3 RED/DARK BLUE FUEL INJECTOR POWER SUPPLY (16 VDC)
4 DARK GREEN 5 TOOTH CPS SENSOR SENSOR SIGNAL
5 WHT/GRN (2011=BRN/WHT) STATOR CPS HARNESS CONNECTOR SENSOR GROUND
TPS CONNECTOR
EXHAUST TEMP. SENSOR
6 BLK/BLU COOLANT TEMP. SENSOR SENSOR GROUND
TMAP SENSOR CONNECTOR
COMMUNICATION CONNECTOR
7 AQUA TPS CONNECTOR TPS SIGNAL RETURN
8 YEL/RED COOLANT TEMP. SENSOR COOLANT TEMP. SIGNAL
9 BLK/WHT DETONATION SENSOR SIGNAL GROUND
10 YEL/WHT TxD SIGNAL (TRANSMIT)

COMMUNICATION CONNECTOR
11 WHT/BLK RxD SIGNAL (RECEIVE)
MAG CRANKCASE INJECTOR DRIVER

14 YELLOW
(DC-CFI-4)
FUEL INJECTOR HARNESS PLUG
15 YEL/WHT MAG CYLINDER INJECTOR DRIVER
16 RED/BLU FUEL INJECTOR POWER (16 VDC)
17 WHITE 2 TOOTH CPS SENSOR SENSOR SIGNAL
18 RED COIL POWER

IGNITION COIL CONNECTOR
19 BLACK COIL GROUND
20 GRAY TMAP SENSOR CONNECTOR INTAKE PRESSURE SIGNAL
21 ORANGE STATOR SYSTEM POWER CONNECTOR FUEL INJECTOR BOOST POWER
22 WHT/BLK EXHAUST TEMP. SENSOR EXHAUST TEMP. SIGNAL
23 PINK TMAP SENSOR CONNECTOR INTAKE AIR TEMP. SIGNAL
TPS CONNECTOR
24 RED/WHT TMAP SENSOR CONENCTOR 5VDC SENSOR VOLTAGE
COMMUNICATION CONECTOR
25 PURPLE DETONATION SENSOR SENSOR SIGNAL
26 ORANGE STATOR SYSTEM POWER CONNECTOR FUEL INJECTOR POWER

Exhaust Temperature Sensor Crankshaft Position Sensors (CPS)

The 5 tooth crank position sensor picks up all 5 flywheel
teeth and determines the following:
Judge direction of rotation (forward and backward)
Ignition advance angle control
Injector drive angle control
Sensor Specifications Excess advance ignition control at reverse
MAG / PTO cylinder detection
Resistance 2.3M @ 392_F (200_C)
Values 76 @ 1652_F (900_C) The 2 tooth crank position sensor picks up 2 flywheel
teeth. It detects the crank angle and obtains minimal
information of the crank angle when control enters into
=T limp home mode 4
The sensors must be in the correct position or the engine
Exhaust Temperature Sensor Torque: will not run. A sheared flywheel key will cause the engine
32 ft-lb (44 Nm) to not start or to shut off (misfire).
Temperature / Air Pressure Sensor (TMAP) Crankshaft Position Sensor Air Gaps
Hard engine starting, erratic reverse operation, and poor
engine performance can occur if the CPS air gap(s) are
outside specification.
TWO-TOOTH CPS
FIVE-TOOTH CPS
AIR GAP
NOTE: The sensor bases are not slotted. Only minor

deflection adjustments can be made.
Sensor Specifications
59_F (15_C) = 3000
= In. / mm.
Pins 1 to 2 (Temperature) 68_F (20_C) = 2500
77_F (25_C) = 2000 Crankshaft Position Sensor Air Gap:
.020"-.030" (0.5-0.8mm)
Pins 1 to 4 (Pressure) 2400 - 8200
Pins 3 to 4 (Pressure) 3400 - 8200
Air Gap Inspection/Adjustment
1. Rotate the crankshaft/flywheel so that an encoder rib
is positioned directly underneath the sensor being
measured.

4.13
2. Insert the blade of a .030" feeler gauge between the Exhaust Valve Solenoid
rib and sensor face. If there is no drag felt on the feeler
gauge, the CPS must be adjusted.
3. To adjust a CPS, use a 8 inch pry bar to carefully
deflect the sensor.
4. Place the tip of the small pry bar between the back of
the sensor and crankcase. insert a .012" feeler gauge
between the sensor face and encoder rib.
IMPORTANT: Do not pry on the individual sensor

wires.
Specifications
Coil Resistance
15 +/- 15% @ 68F (20C)
PRY BAR (WHT/YEL to RED)
FEELER GAUGE
Ignition Coils
5. Gently pry the sensor towards the encoder rip until the
gauge begins to bind between the components.
6. Re-measure the air gap. The gap should be between
.020-.030.
Specifications
DC-CFI 4 DC-CFI 2
Primary Coil
0.20 +/- 15% 0.45 +/- 15%
Resistance @ 68F (20C) @ 68F (20C)
(Black to White)
Secondary Coil
Resistance
6.3k +/- 15% 18k +/- 15%
(Without Plug Cap/ @ 68F (20C) @ 68F (20C)
Black to High Tension
Lead)
Plug Cap Resistance 5k +/- 15% @ 68F (20C)

Engine Coolant Temperature Sensor Throttle Body Removal
4
Sensor Specifications
1. Remove the oil tank/clutch cover assembly.
Operating Temperature -22_F - +248 _F 2. Remove the airbox assembly.
Range (-30_C - 120_C) 3. Pinch off the coolant lines with the hose pincher tool
2.4 - 2.6K @ 68_F (20_C) PN PU-45149.
Resistance 4. Remove the coolant hoses from the throttle body.
(Measure in stirred water)
Disconnect the TPS harness connector.
Installation Torque 29 ft-lb (39.2Nm)
5. Loosen the intake boot clamps and pull the throttle
body upward. Locate the oil pump linkage arm. Pop
Knock (DET) Sensor the rod end off the throttle body cam.
6. Loosen the throttle cable lock nut and remove the
cable from the throttle body.
7. Remove throttle body.
8. During installation, verify the oil pump lever is not
rotated over-center before installing the linkage arm
on to the throttle body.
=T
Knock Sensor Screw Torque:
168 in-lb (19 Nm) Install screw clean and dry.

4.15
DC-CFI-4 FUEL INJECTORS/FUEL Fuel Pressure Gauge (PU-43506-A)

RAIL PU-43506-A
CONNECT TO ADAPTER
Fuel Injectors
Fuel Pressure Gauge Adapters
A
OEM PART NUMBER
Specifications B
Resistance 12 @ 68_F (20_C)
Fuel Rail Bleeding / Pressure Testing

C
All CFI engine fuel return hoses feature an inline Schrader
valve that can be used to bleed the fuel system pressure
and observe fuel system pressure when using the fuel
pressure gauge and specified adapter. A = 314249 (.305-32 shallow core fitting/adapter
supplied with PU-43506-A Fuel Pressure Gauge)
SCHRADER VALVE
B = PS-48617 (.305-32 deep core fitting)
TO FUEL TANK
C = PS-48762 (7/16-20 fitting)
1. Select the appropriate adapter.
2. Connect the adaptor to the fuel return hose Schrader
valve.
3. Connect the adapter to the fuel pressure/bleed tool
gauge.
T0 FUEL RAIL 4. To observe running fuel system pressure, start the
engine and compare reading to the specification.
NOTE: Observe pressure reading at idle and while

operating the vehicle.
Fuel Pressure Gauge/Adapters = In. / mm.

GAUGE/
YEAR / MODEL ADAPTERS
BLEED TOOL Fuel System Pressure:
58-60 (4.0-4.1)
600 DC-CFI-4 314249
PRO-RIDE (.305-32 Shallow Core fitting PU-43506-A
Shallow Core supplied with PU-43506-A)

5. To bleed the fuel system pressure after the engine is Fuel Rail/Injector Removal/Installation
stopped, place the tools bleed hose into an
appropriate fuel handling container. Open the valve to NOTE: Leave protective caps installed until
release the pressure and drain residual fuel. instructed to remove. Avoid touching the tip of the
6. Close the valve, then remove the gauge and adapter injector.
from the fuel hose Schrader valve. Replace the
Schrader valve dust cap.
BLUE OR BLACK O-RING
Disconnect Fittings
OEM PART NUMBER
The fuel hoses feature disconnect fittings that require

special tools to remove.
The fuel line disconnect tool kit, PS-47152, supplies one
5/16 and one 3/8 quick disconnect tool. These tools are
also commercially available at local auto parts stores. BROWN OR GREEN O-RING
4
PS-47152 GREEN BUSHING
600 INJECTOR KITS
INJECTOR KITS COLOR
2203894-053 Yellow
1. To disconnect a fuel hose from the fuel pump, or fuel
rail, insert the tapered end of either the 5/16 or 3/8 2203894-027 Blue
tool into the female housing. 2203894-015 Red
2. Push the tool into the housing to release the spring
clamps. Carefully separate the hose from the A fuel injector, regardless of color code, can be accurately
connection. identified by the OEM part number stamped on plastic
injector housing.
3/8 DISCONNECT TOOL
600 = OEM PN 1203491
When replacing a faulty fuel injector, always verify the part
number of the injector for the engine application and use
the same color code. If replacing an injector with a different
color code, all of the fuel injectors must be replaced with
the new color so all four injectors are the same color.
After replacing the injectors, the ECU must be re-flashed
so the fuel calibration map matches the new color coded
fuel injectors.
CAUTION
ALWAYS CHECK THE INJECTOR PART NUMBER TO

3. Reconnect the fuel hoses by coating each hose end VERIFY ENGINE APPLICATION REGARDLESS OF COLOR
with a light film of two stroke engine oil. CODE.
4. Carefully install the male end of the hose into the NEVER RUN THE ENGINE WITH DIFFERENT COLOR-
CODED FUEL INJECTORS. SEVERE ENGINE DAMAGE
center of the female housing. Firmly push the hoses
WILL OCCUR.
together until the male nozzle fully seats behind the
ALWAYS VERIFY THE ECU CALIBRATION FILE MATCHES
spring tabs and an audible click is heard. THE FUEL INJECTOR COLOR CODE.
5. Grasp both hoses and gently pull to verify positive
engagement. 1. Depressurize the fuel rail. See Fuel Rail Bleeding /
Pressure Testing on page 4.16.

4.17
2. Remove the panduit straps as shown. NOTE: Make sure that the green bushing comes out
with the injector. If it does not, look inside the
injector bore.
BLUE OR BLACK O-RING
BROWN OR GREEN O-RING
GREEN BUSHING
NOTE: The engine must be removed from the 6. Measure from the end of the injector (as shown
engine compartment to access the lower two fuel below)
injectors. 3" (76.2mm) and cut the injector off.
3. Remove the hex screws securing the fuel rail to the

cylinders.
3 (76.2mm)
7. Strip the harness end injector wire covering .25" -

.375" (6.35 - 9.525mm).
8. Crimp the ends of the new injector firmly on to the wire
harness.
4. If replacing a lower injector, remove the two bottom

screws bolts from the lower fuel rail.
5. Remove the failed injector(s).

9. Tape exposed wire and splices.
4
10. Apply oil to the fuel injector o-rings.
11. Remove the protective caps. Install the injector(s) into
the fuel rail. Verify the injector(s) are fully seated.
12. Insert the fuel rail, with injectors into the engine.
13. Apply a light amount of 262 Loctite to the fuel rail
fasteners and torque to specification.
=T
Fuel Rail Hex Screw Torque: 9 ft-lb (12Nm)
14. Replace the harness to the original routing and apply

panduit straps back to the original locations.
NOTE: Refer to Step 2 for proper routing and strap

location.
15. Install the engine if it was removed.

16. If different color injectors were installed, re-flash the
ECU to the new color code.

4.19
Fuel System Assembly
RETURN HOSE w/SCHRADER VALVE
SUPPLY HOSE w/FILTER
FILTER BRACKET
P-CLAMP (INSTALLED UNDER FILTER BRACKET)
CYLINDER (PORT) INJECTORS A
CRANKCASE INJECTORS
THROTTLE POSITION SENSOR (TPS)
=T
A: 9 ft-lb (12 Nm)
B: 1.5 ft-lb (2 Nm) Position p-clamp behind bracket.

DC-CFI-2 FUEL INJECTORS/FUEL When replacing a fuel injector assembly, match the fuel
RAIL injector color code with the service part number listed in
the table below. If replacing a fuel injector assembly with
Fuel Injectors/Assembly one of a different color code, the ECU must be flashed with
the new color-coded ECU map.
DC-CFI-2 engines feature a dual fuel injector/wiring
harness assembly. Fuel injector replacement requires NOTE: In addition to the fuel injector o-rings, an
removing both fuel injectors/harness and installing a new isolator o-ring (2011) or bushing (2012) is installed
assembly. Fuel injectors are not supplied individually. inside each cylinder fuel injector bore.
Harness cutting and splicing is not required.
2011 800 DC-CFI-2 INJECTOR KITS
CAUTION INJECTOR KITS COLOR
2011 and 2012 fuel injectors are different and not

interchangeable. Severe engine damage will occur if the
4013046-053
4013046-027
Yellow
Blue
4
incorrect fuel injectors are installed.
NOTE: 4013046-015 (RED) fuel injectors are no
longer available. Order and install either YELLOW or
BLUE injectors. After installing new injectors,
O-RINGS (7.52MM ID) reflash the ECU to match the new fuel injector color
code.
2012 600/800 DC-CFI-2 INJECTOR KITS
INJECTOR KITS COLOR
4013258-053 Yellow
4013258-027 Blue
4013258-015 Red
ISOLATOR O-RING (12.4MM ID)
2011 FUEL INJECTORS w/HARNESS
O-RING (BLACK)
O-RING (BROWN)
GREEN BUSHING
2012 FUEL INJECTORS w/HARNESS

4.21
Fuel Rail Bleeding / Pressure Testing Fuel Pressure Gauge Adapters
DC-CFI-2 PRO-RIDE models feature a Schrader valve A

located on the fuel pump that can be used to bleed the fuel
system pressure and observe fuel system pressure when
using the fuel pressure gauge and specified adapter.
SCHRADER VALVE B
A = 314249 (.305-32 shallow core fitting/adapter

supplied with PU-43506-A Fuel Pressure Gauge)
B = PS-48617 (.305-32 deep core fitting)
C = PS-48762 (7/16-20 fitting)
1. Select the appropriate adapter.
2. Connect the adaptor to the fuel return hose Schrader
valve.
3. Connect the adapter to the fuel pressure/bleed tool
gauge.
Fuel Pressure Gauge/Adapters 4. To observe running fuel system pressure, start the
engine and compare reading to the specification.
GAUGE/
MODEL ADAPTERS
BLEED TOOL NOTE: Observe pressure reading at idle and while
operating the vehicle.
DC-CFI-2
PS-48762
PRO-RIDE PU-43506-A
(7/16-20 fitting)
= In. / mm.
Fuel Pressure Gauge (PU-43506-A)
PU-43506-A
Fuel System Pressure:
CONNECT TO ADAPTER 58-60 (4.0-4.1)
5. To bleed the fuel system pressure after the engine is

stopped, place the tools bleed hose into an
appropriate fuel handling container. Open the valve to
release the pressure and drain residual fuel.
6. Close the valve, then remove the gauge and adapter
from the fuel hose Schrader valve. Replace the
Schrader valve dust cap.

Disconnect Fittings Fuel Rail Microdampers
The fuel hoses feature disconnect fittings that require The DC-CFI-2 fuel rail assembly contains two fuel
special tools to remove. pressure microdampers. The microdampers suppress
fuel pressure pulses that occur when each fuel injector is
The fuel line disconnect tool kit, PS-47152, supplies one
activated.
5/16 and one 3/8 quick disconnect tool. These tools are
also commercially available at local auto parts stores. The microdampers are considered life of engine
components and servicing is not recommended. If a
PS-47152
microdamper is removed, apply a light film of two-stroke
engine oil to the o-ring during installation.
Torque clamp fasteners to specification.
A
1. To disconnect a fuel hose from the fuel pump, or fuel
rail, insert the tapered end of either the 5/16 or 3/8
4
CLAMPS
tool into the female housing.
2. Push the tool into the housing to release the spring
clamps. Carefully separate the hose from the
connection.
3/8 DISCONNECT TOOL
MICRODAMPERS w/O-RINGS
FUEL RETURN
PLUG
3. Reconnect the fuel hoses by coating each hose end

with a light film of two stroke engine oil.
4. Carefully install the male end of the hose into the FUEL RAIL
center of the female housing. Firmly push the hoses
together until the male nozzle fully seats behind the
FUEL SUPPLY
spring tabs and an audible click is heard.
5. Grasp both hoses and gently pull to verify positive
engagement.
=T
A: 3.3 ft-lb (4.5 Nm)
NOTE: A threaded plug is located on the MAG end of

rail. Do not remove plug.

4.23
Fuel Rail/Injector Removal and Installation
FUEL INJECTOR ASM.
FUEL RETURN
FUEL SUPPLY
2011-ISOLATOR O-RING
A 2012-GREEN BUSHING
A FUEL RAIL ASSEMBLY
8. Carefully pull the rail away from the engine and

=T injectors. Remove the injectors from the cylinder.
A: 9 ft-lb (12 Nm) NOTE: Always use new o-rings/isolators after fuel
injectors have been removed.
Removal/Installation Process
9. Using a pick, remove the two fuel injector isolators or
NOTE: Do not touch fuel injector inlet/outlet. Leave bushings from the injector ports in the cylinder.
protective caps in place while handling. Discard the isolators/bushings.
10. Remove the fuel injector o-rings from fuel injectors.
1. Open the door panels and remove the hood Discard the fuel injector o-rings.
assembly.
11. To reinstall the fuel rail assembly, lightly coat two new
2. Relieve fuel system pressure. fuel injector isolators with two-stroke engine oil. Install
3. Disconnect the fuel supply and return hoses from the the new isolators or bushings into the cylinder injector
fuel pump. ports.
4. Remove the ECU, ECU bracket, and oil tank from the 12. Install four new oil-coated fuel injector o-rings.
clutch cover assembly. 13. Install both fuel injectors into the cylinder. Carefully
5. Remove the air box intake tube and top to gain access install the fuel rail assembly.
to the fuel rail. 14. Tighten fuel rail screws evenly. Once both screws are
6. Disconnect the fuel injector assembly wiring harness seated, torque to specification.
connector. 15. Reconnect the fuel injector harness wiring connector.
7. Remove the two screws that mount the fuel rail to the 16. Reinstall the air box components.
cylinder.
17. Install the oil tank, ECU bracket, and ECU.
18. Reconnect the fuel supply and return fuel hoses on
the fuel pump.

FUEL TANK/PUMP SERVICE
2010 Fuel Tank/Pump Assembly
A SEAT MOUNT BRACKET

CAP
VENT/VAC HOSE
D
FUEL TANK BRACKET D

4
D
FUEL TANK
B
PFA NUT
C
PFA GASKET
PUMP ASSEMBLY
=T
A: 10 ft-lb (14 Nm)
B: 6 ft-lb (8 Nm)
C: 28 ft-lb (38 Nm)
D: 7 ft-lb (10 Nm)
SERVICE PARTS:
Fuel Pump Assembly - 2520951
Pickup/Sock Assembly (w/clamps and cable ties) -
2204376
PFA Gasket - 5413063
CAUTION
ALWAYS REPLACE PFA GASKET WITH NEW

GASKET AFTER REMOVING FUEL PUMP.

4.25
2011-2012 RUSH/Switchback Fuel Tank/
Pump Assembly

CAP
D WASHER
VENT/VAC HOSE
FUEL TANK BRACKET D
D
FUEL TANK
B
PFA NUT
C
PFA GASKET
PUMP ASSEMBLY
=T
A: 10 ft-lb (14 Nm)
B: 6 ft-lb (8 Nm)
C: 28 ft-lb (38 Nm)
D: 7 ft-lb (10 Nm)
SERVICE PARTS:
Fuel Pump Assembly - (600 Rush) 2520951
(800 Rush) 2521107
Pickup/Sock Assembly (w/clamps and cable ties) -
2204376
CAUTION


2011-2012 Switchback Assault/RMK Fuel
Tank/Pump Assembly

CAP
D
FUEL TANK
VENT/VAC HOSE
C
PFA NUT
PFA GASKET
PICKUP ASSEMBLY
PUMP ASSEMBLY
=T
A: 10 ft-lb (14 Nm)
B: 6 ft-lb (8 Nm)
C: 28 ft-lb (38 Nm)
D: 7 ft-lb (10 Nm)
SERVICE PARTS:
Fuel Pump Assembly (w/gasket) - 2521142
Pickup Assembly (w/clamps-gasket) - 2520873
CAUTION


4.27
Fuel Tank Service 9. Remove the old gasket and discard.
1. Remove the tank cap and siphon the fuel in the tank CAUTION
into a suitable container.
2. Remove the seat assembly ALWAYS REPLACE PFA GASKET WITH NEW
3. Remove the door panels and hood. GASKET AFTER REMOVING FUEL PUMP.
4. Remove the console.
10. Clean the tanks gasket mating surface with isopropyl
5. On RUSH models, remove the two screws attaching alcohol. Allow the surface to dry completely.
the fuel tank bracket to the steering post assembly.
11. Install a new gasket ensuring the inside portion of the
6. Disconnect the fuel supply and return hoses from the gasket hooks onto the bead on the inside diameter of
fuel pump. Disconnect the fuel pump power/level the neck.
sender wire harness connector.
12. Remove any containments from the gasket with
7. Remove the fuel tank assembly from the snowmobile. isopropyl alcohol.
8. Inspect the tank for signs of damage/excessive wear. 13. Carefully place the PFA back into the tank. Push the
Inspect the foam pads that the tank rests on. Replace float assembly against the hoses to fit it into the hole.
pads if torn, missing, or damaged.
14. Hand tighten the PFA nut keeping the arrow between
9. Installation is the reverse of removal. the PFA alignment marks.
Fuel Pump Service RETURN FITTING
1. Siphon the fuel out of the fuel tank into a suitable SUPPLY FITTING
container.
2. Remove the door panels, hood, and console.
3. Disconnect the positive (+) battery cable from the
battery if applicable.
4. Bleed the pressure from the fuel rail. See Fuel Rail
Bleeding / Pressure Testing on page 4.16.
5. Disconnect the fuel supply and return hoses from the
pump flange. See Disconnect Fittings on page 4.17. ARROW
6. Disconnect the wiring harness. ALIGNMENT LINES
7. Using the PFA spanner wrench and nut socket (PS-
48459), carefully remove the PFA nut.
15. Using the PFA spanner wrench and nut socket
(PS48459), tighten the PFA to specification.
=T
PFA Nut Torque: 28 ft-lb (38 Nm)
CAUTION
Verify the PFA nut does not make contact with the fuel
tank after applying torque.
16. Fuel tank installation is the reverse of removal. Always

test the PFA gasket seal before tank installation by
8. Carefully extract the PFA out of the tank making sure performing a pressure check.
the float and fuel hoses do not become kinked or bent.

Fuel Pump/Level Sender Test Specifications 4. Once the tank is pressurized, saturate the area
around the PFA gasket with a mixture of water and
The fuel level sender resistance can be checked using a mild detergent.
multitester set to read resistance (OHMS). 5. If any bubbles form, re-check the PFA nut torque. If
Measure resistance at the fuel pump harness connector bubble formation continues, the PFA gasket will have
between pin 2 (WHITE/BLACK) and pin 4 (PINK/BLACK). to be replaced, or tank replacement is required.
ARM UP/GAUGE READING FULL = <8 NOTE: There may be bubbles present from the initial
FLOAT HEIGHT FROM BOTTOM OF TANK = 345.3mm application of leak detector. Blow on the bubbles to
+/-16.4 pop them. Watch for new bubble formation. New
ARM MIDDLE/GAUGE READING 1/2 = 40.7+/- 1.5 bubble formation may be very small so look closely.
FLOAT HEIGHT FROM BOTTOM OF TANK = 213.2mm Apply additional water/detergent solution if required.
+/- 23.2
ARM DOWN/GAUGE READING EMPTY = 91.5 +/- 1.5
FLOAT HEIGHT FROM BOTTOM OF TANK =
4
89.6mm +/- 20.8
Fuel Tank Pressure Test

1. Connect a Mity Vac hand pump to the fuel tank vent
fitting.
2. Connect a eight-inch piece of 5/16 fuel hose and two
gear clamps across the fuel supply and return fittings
at the fuel pump flange.
3. Pressurize the tank to 5 PSI (34 Kpa).
NOTE: Fuel tank deformation will occur when the

tank is pressurized.
WARNING
Do not over-pressurize the fuel tank past 6 PSI

(41 Kpa).
NOTE: Using a hand pump to pressurize the fuel

tank may take a very long time. The installation of an
in-line Schrader Valve (PN: 2872602) and the use of a
low pressure pump (bicycle tire pump) is
recommended.

4.29
Rush/Switchback Fuel Pump Pickup NOTE: Model year 2010 Rush fuel pump assembly
Orientation service parts feature the rotated fuel pickup
assembly.
When servicing the Rush fuel pump pickup assembly or
troubleshooting an issue with a stuck low fuel gauge MY10 Rush Pickup Assembly:
display on the MFD gauge, verify the pickup assembly is
orientated as shown in the MY11 Pickup Assembly
illustration below.
PICKUP ASSEMBLY MAY INTERFERE

WITH FUEL SENDER FLOAT
MY11 Rush Pickup Assembly:
PICKUP ASSEMBLY ROTATED

FUEL SENDER FLOAT CLEAR FROM 45 DEGREES
PICKUP ASSEMBLY
ROTATE BOTH HOSES BEFORE INSTALLING

CLAMPS

DIGITAL WRENCH DIAGNOSTIC
SOFTWARE
Digital Wrench Diagnostic Software Overview
IMPORTANT: Refer to Section 2, 3 and 4 in the Instruction Manual provided in the Digital Wrench Diagnostic
Kit to install the Polaris Digital Wrench diagnostic software on your computer.
The Digital Wrench diagnostic software allows the Reflash ECU calibration files
technician to perform the following tests and observations: Perform guided diagnostic procedures
View or clear trouble codes Create customer service account records
Analyze real-time engine data Perform output state control tests
Special Tools
4
DIGITAL WRENCH DIAGNOSTIC SOFTWARE PART NUMBER
PC/Laptop with Microsoft Windows 98/XP-SP2/Vista/7 Commercially Available
Digital Wrench Diagnostic Kit PU-47063-B
Digital Wrench Software: PU-48731
Standard Interface Cable: PU-47151
USB-Serial Adapter Cable: PU-50621
PU-47063-B (listed above) INCLUDES: SmartLink Module/Cable Kit: PU-47471
PU-47471 INCLUDES:
SmartLink Module: PU-47468
SmartLink Serial Cable: PU-47470
SmartLink CAN Interface Cable: PU-47469
Chassis Power-Up Harness PS-47296-A
Dual Power-Up Adapter/Fuel Pump Prime Harness PS-50805
12 VDC Battery Commercially Available
Reflash Enable Jumper PS-50361
Diagnostic Software Version Guided Diagnostics Available

Always use the most current version of the Digital Guided diagnostics are available within Digital Wrench
Wrench software to ensure you have the latest updates for all supported Trouble Codes (that is, any fault that will
or enhancements. New reprogramming files and guided turn on the Check Engine indicator).
diagnostic procedures are added to these updates as they
In addition, guided diagnostics are also available for many
become available. For information on how to determine if
other electrical sub systems.
you have the latest update available, refer to Digital
Wrench Version and Update ID. Diagnostic procedures are added to subsequent versions
of Digital Wrench as they become available. Check your
ECU Replacement release version often and upgrade when available to be
sure you are using the most current software available.
Although the need for ECU replacement is unlikely, a
specific replacement procedure is required to ensure that
all essential data contained within the original ECU is
transferred to the replacement ECU.
Refer to procedure and carefully follow all instructions
provided in Digital Wrench.

4.31
Digital Wrench Communication Errors 2. Remove the protective cap from the Digital Wrench
connector (A) and then connect the Vehicle Interface
If you experience problems connecting to a vehicle or any Cable to the diagnostic connector.
Digital Wrench related problem, visit the Digital
Wrench Knowledge Base for the most current
troubleshooting information, FAQs, downloads and
software updates at: http://polaris.diagsys.com/.
ECU POWER
3. Connect the chassis power-up harness to a fully

charged 12VDC battery. Connect the chassis power-
up harness to the ECU POWER connector.
NOTE: An internal relay within the harness prevents

Digital Wrench - Diagnostic / Power reverse polarity damage in the event the alligator
Connectors clamps are connected to the battery incorrectly.
The diagnostic/power connectors are located behind the CHASSIS POWER-UP HARNESS
left engine compartment door. PS-47296-A
1. Assemble the SmartLink Module and attach the PC
Interface Cable to your PC/laptop.
DUAL PWR/FUEL PUMP PRIME

PS-50805
4. When battery power is connected successfully, the

SmartLink status LED will blink on once.

NOTE: Connecting the chassis power-up harness to 2. Proceed to http://polaris.diagsys.com to see if a
the DC POWER TEST plug will power the DC chassis newer update is available.
circuit.
CAUTION
Do not connect DC power to the AC power test plug. This

plug is for testing the AC power circuit with a digital volt/ Digital Wrench Update
ohm meter. Severe electrical system damage will occur.
Digital Wrench Serial Number Location

Open the configuration screen by clicking on the wrench
icon. The serial number is located on the right side of the 3. If a newer update is available, it should be
4
screen. downloaded before using Digital Wrench (see
Digital Wrench Updates).
Digital Wrench Updates

Updates are released for Digital Wrench via the Internet
at: http://polaris.diagsys.com. The Digital Wrench
web site can also be accessed through the dealer web site
at: www.polarisdealers.com.
Digital Wrench Version and Update ID NOTE: Only authorized Polaris dealers and
distributors can access the dealer web site.
Knowing what Digital Wrench version and update is
installed will help determine which updates are required. 1. Log on to www.polarisdealers.com.
NOTE: Versions and updates are subject to change. 2. Locate the Service and Warranty drop-down
menu.
1. Open the Digital Wrench software. Locate the 3. Click on Digital Wrench Updates.
version ID shown on the lower right side of the Digital
Wrench start-up screen.
Version
4. The Digital Wrench portal web site should appear

in a new web browser.

4.33
5. Click on Digital Wrench Version Updates. should match the update you just downloaded.
Digital Wrench Update
IMPORTANT: You must already have the current

version installed before adding an update. Updates
will not install if you are using an older version loaded
on your PC.
6. If the update file date listed is newer than your current

version and update (see Digital Wrench Version Version
and Update ID), download the file.
NOTE: Versions and updates are subject to change.
7. Click on the link shown above, save the file to your

hard disk and then double-click the icon to start the
update process.
NOTE: Do not RUN or OPEN the file the web site.

Select SAVE and download to your PC before
running the install.
8. When the update is complete, the version shown on

the right side of the Digital Wrench start-up screen

Digital Wrench Feature Map

4.35
Updating Digital Wrench 5. Locate and click on the version of Digital Wrench
currently running on the PC or laptop.
Updates are released for Digital Wrench via the Internet.
The Digital Wrench update website can be found by
accessing the dealer Internet site at:
www.polarisdealers.com.
6. Locate and click on the update file. Save the file to the
PC or laptops desktop.
NOTE: Only authorized Polaris dealers and

distributors can access the dealer Internet website.
1. Log on to www.polarisdealers.com.
2. Locate the SERVICE AND WARRANTY drop-down
menu.
3. Click on DIGITAL WRENCH UPDATES.
4. The next screen is the Digital Wrench portal website.
7. Locate the update file on the desktop. Double-click
The following selections can be made on the update and select RUN on the icon to install the update.
website: 8. Delete the file after performing the update.
Home - Digital Wrench Home Page
Downloads - Listing of current filesets and Digital NOTE: Delete the update file from the desktop when
Wrench downloadable updates finished.
Forums - Member generated knowledge base
Search - Website search engine
Topics - Vehicle-specific Digital Wrench
information

Version Identification Vehicle History Information
1. Start the Digital Wrench software. Selecting the Vehicle History Information option displays
2. Locate the version ID on the title screen. the following information:
Throttle Position (TPS) history
Engine RPM history
Engine run time hours
Engine overheat occurrences
Engine overheat misfire protection mode
occurrences
Engine run time in limp home modes
4
3. The version ID number should match the Digital
Wrench update name.
Special Tests Menu

The SPECIAL TESTS (Tool Box Icon) in Digital Wrench
gives the service technician the following options:
Vehicle History Information
Output State Control Service Report
TPS Set Procedure
Selecting Service Report from the SPECIAL TESTS
Service Report MENU generates a report of all of the current ECU input/
ECU Replacement output values, model/calibration/software information,
Security Functions (2012 Only) and diagnostic trouble codes.
Engine Controller Reprogramming
Vehicle Information
Feature Configuration/Registration
Technicians can add the VIN or customers name to the

customer name field and then save the service report as
a .txt file on their laptop/PC.
NOTE: Special Tests menu selections will populate Clicking on View Current will refresh the report
according to vehicle selected. information. Selecting View Saved will access any saved
service report .txt files saved on the laptop/PC.

4.37
ECU Replacement After completing the ECU replacement procedure, reflash
the ECU with the current ECU calibration file for the
Use the ECU replacement feature whenever installing a vehicle using the engine controller reprogramming
new service ECU on the vehicle. Follow the guided procedure.
procedures in Digital Wrench to perform the ECU
replacement procedure. NOTE: ECU replacement only copies the model ID
number to the new service ECU. Vehicle history and
NOTE: The ECU replacement function initializes the calibration files are not copied over.
new service ECU. Service ECUs cannot be reflashed
without first performing this procedure. Engine Controller Reprogramming (Reflash)
Process Overview
The reprogramming feature is in the Special Tests menu
on the Digital Wrench screen. Start Digital Wrench
and click on the Special Tests menu icon (red tool box). A
technician should be familiar with the process and with
computer operation in general before attempting to
reprogram an ECU.
The Digital Wrench Engine Controller Reprogramming
(or Reflash) feature allows reprogramming of the ECU
fuel and ignition map. To successfully reprogram the ECU,
an Authorization Key must be obtained by entering a
Request Code in the box provided on the Reflash
Authorization site. The Request Code is automatically
The procedure copies the model ID number from the generated by Digital Wrench during the reprogramming
original ECU, and then copies it to the new service ECU. process. The Reflash Authorization site is located under
the Service and Warranty drop down menu on the
IMPORTANT: The procedure cannot be reversed once dealer website at: www.polarisdealers.com.
the model ID number is copied to the new service
ECU. The service ECU will forever retain the model ID IMPORTANT: Failure to follow the reprogramming
number copied on it using this procedure. instructions completely and correctly can result in an
engine that does not run! Replacement ECUs are
If communication with the original ECU cannot be programmed as no-start and require a reflash for
established, Digital Wrench will guide the user through a them to work.
manual model ID selection procedure. Pay careful
Reprogramming (Reflash) Tips:
attention to the model selected when using the manual
procedure. BATTERY VOLTAGE: The majority of problems
with reprogramming can be attributed to a low
battery. Be sure the battery voltage (no load) is at
least 13 volts and at least 12.5 volts with the key
ON. Connect a battery charger if necessary to
bring voltage level above minimum. Fully charge
the battery before you attempt to reprogram.
DEDICATED LAPTOP: Best results are obtained
using a laptop computer that is dedicated to
Digital Wrench. A laptop that is used by a
variety of people and in several applications
around the dealership is more likely to cause a
reprogramming problem than one dedicated to
Digital Wrench diagnostics only.
OBTAINING THE LATEST UPDATE:
Reprogramming updates are provided periodically
and contain the most recent calibrations (see
Digital Wrench Updates).

CLOSE NON-ESSENTIAL PROGRAMS: Polaris NOTE: New service replacement ECUs are
recommends that you DO NOT install non- programmed as no-start and must be reflashed for
essential programs on a Service Department the engine and fuel injector code.
laptop. Camera detection software, Virus
Scanners, Tool Bars, etc. may clog up memory if 1. Verify the most current update is downloaded and
running in the background and make it harder for loaded into Digital Wrench.
the diagnostic software to operate. 2. Connect the communication cables to the
KNOW THE PROCESS: If you are not familiar with snowmobile connectors.
the entire reprogramming process, review the 3. Start Digital Wrench. Select the model year and
HELP section of the diagnostic software before vehicle using the CHANGE VEHICLE TYPE button.
you attempt reprogramming. Click on the ? on the 4. Click on the SPECIAL TESTS icon.
tool bar or press F11. The information in the on-
line help is the most current and complete 5. Click on ENGINE CONTROLLER
information available. This should be your first REPROGRAMMING.
step until you are familiar with the process.
COMMUNICATION PROBLEMS: If you have had
6. Select the engine model and color of the injectors 4
installed on the engine. Record the 7 digit injector part
problems communicating with a vehicle while number. Click CONTINUE.
performing diagnostic functions, do not attempt
reprogramming until the cause has been identified NOTE: All fuel injectors on the engine must share
and fixed. Check all connections, and be sure the same color code.
battery voltage is as specified.
The most-current reflash files will be located at the
Proceed to http://polaris.diagsys.com for top of the list and will not have SUPERSEDED in
specific information and FAQs on how to the file name.
troubleshoot communication problems.
Files with SUPERSEDED in the file name denote
older calibrations.
7. A request code will be generated. Record the code.
8. Access www.polarisdealers.com. Locate REFLASH

DONT DISTURB THE PC: While reprogramming AUTHORIZATION under the SERVICE AND
is in progress, dont move the mouse and dont WARRANTY drop-down menu.
touch the keyboard. The process only takes a few
minutes, and is best left alone until complete.

4.39
9. Enter the REQUEST CODE generated by Digital 14. Copy the code, and then enter the code into the
Wrench into the information box. AUTHORIZATION box in Digital Wrench. Click
CONTINUE.
10. After entering the REQUEST CODE, click

CONTINUE. 15. The reflash process will begin. Verify all connections
are properly made. Do not touch anything during the
process.
16. Verify the reflash was a success by comparing the
software ID number listed under the CUSTOMER
AND VEHICLE IDENTIFICATION button with the
number recorded in step 6.
11. The next screen asks for the following information:

Desired Reflash File
Vehicle VIN
Customer Name, Address, Zip Code
12. After entering the required information, click
CONTINUE.
13. If all of the information was accurate, the website will NOTE: If security function was enabled on vehicle
generate and AUTHORIZATION CODE. prior to replacing the ECU and/or performing the
engine controller reprogramming, the Security
Enable procedure will have to be completed to
activate security in the ECU.

Digital Wrench Data Grid Screenshots
2010 RUSH 600 - Engine at Idle (75 F shop room
temperature/1,060 ft. ASL)
The data grid can display numerous sensor/switch inputs Does the TPS voltage transition smoothly when
and outputs. Not all are shown in the screenshots above. the throttle lever is pushed?
Use the (+) and (-) button to add and remove data Is the Injector/ignition voltage 15.5-16.5 VDC?
parameters.
Always verify the reading against known information.
Some of the items to look for include:
Is the barometric pressure, intake air temperature,
and engine coolant temperature accurate?
Is the TPS voltage (at idle) 0.95 +/- .01 VDC?

4.41
THROTTLE POSITION SENSOR
Throttle Position Sensor (TPS) Overview
CAUTION
The throttle position sensor (TPS) is set at the time of throttle body manufacture. TPS adjustments should only be
made if the TPS was loosened, repositioned, or replaced.
Any adjustments made to the idle air gap screw, TPS sensor, or throttle synchronization screw should only be
performed when directed to so by the Digital Wrench Diagnostic Software.
THROTTLE BODY
ENGINE
TPS
The Throttle Position Sensor (TPS) is a 5 VDC potentiometer (variable resistance) type sensor mounted to the PTO side
of the throttle body. The internal components of the sensor are connected to the throttle shaft. The TPS output signal
changes as the throttle plates are opened and closed by the operator. The ECU uses this signal to determine the position
of the throttle plates.
The TPS is set at the factory based on a throttle body idle air gap flow specification. Adjustments should only be
performed when:
TPS is replaced
TPS or throttle body is mis-adjusted
Troubleshooting erratic or inconsistent engine idle, and/or engine performance
NOTE: Follow these guidelines whenever working with the TPS:
Use Digital Wrench when checking the TPS voltage. Do not use any other diagnostic tool.
Disconnect throttle cable from the throttle lever. If the TPS idle voltage changes, the throttle cable is too tight.
Readjust throttle cable.
Verify the throttle cable is not pulling on the throttle plate cam. Turn the throttle cable in line adjuster clockwise to
loosen the cable. If the cable continues to pull on the throttle plate cam, readjust the throttle cable threaded
barrel on the throttle body.
All engine management sensors/switches must be connected to obtain accurate TPS voltage readings.
Use a fully charged 12VDC battery to power the engine management system

TPS Tests
Two tests can be performed to quickly determine if further testing is required.
TEST 1: TPS Idle Voltage
1. Connect Digital Wrench to the vehicle. Confirm the throttle lever free play is set to specification, and the throttle
cable is not pulling on the throttle plate cam.
2. Click on the DATA GRID ICON to view the current sensor readings.
3. Locate the TPS VOLTAGE reading and compare it to the specification for the vehicle. Verify SENSOR REFERENCE
VOLTAGE is 4.9-5.0 VDC.
TPS Idle Base Setting Voltage

MODEL SPECIFICATION
600 DC-CFI Engine .94-.96 VDC

800 DC-CFI Engine .93-.95 VDC
TEST 2: TPS Signal Sweep
Utilize the sensor graph function to view the TPS voltage return signal voltage as a line graph.
1. Slowly move the throttle lever in and out. The return signal line should change without any erratic jumps or gaps.
2. If erratic jumps or gaps are encountered, inspect the wiring, and connector pins at the sensor and ECU connector.
3. If no wiring problems are found, inspect the TPS to verify it is securely mounted to the throttle body. If loose, it will
have to be readjusted.
4. Replace the TPS if steps 3 and 4 do not resolve the issue.

4.43
TPS Set Procedure Menu
The TPS Set Procedure Menu must be accessed to perform the following procedures:
Idle Voltage Setting Adjustment

Base and Idle Voltage Adjustments - TPS Replacement
Throttle Body Synchronization-Full Adjustment Procedure
To access the TPS Set Procedure Menu, click on the Special Tests (Red Tool Box) button.
Select Menu Option 3 - TPS Set Procedure

The next screen will display the current idle voltage setting. The text will match the voltage specification required by the
vehicle.
If the voltage is within specification, the dialogue box will indicate the current TPS setting is within specifications, and
the CONTINUE button will be RED.
If the voltage is outside specification, the dialogue box will indicate the current TPS setting is outside specifications, and
the CONTINUE button will be GREEN.
If the technician clicks on the RED CONTINUE button on the TPS Setting screen, the following screen will be displayed.
This screen prompts the user to verify they want to make an adjustment to the TPS knowing the idle voltage setting is
within specification.
Clicking NO will end the procedure and return the user to the Special Tests Menu. Clicking YES will display the TPS
Initialization Procedure screen.

4.45
This is the TPS Initialization Procedure screen. A detailed description of each procedure is outlined below.
IDLE SETTING
Access the Idle Setting procedure to set the idle speed voltage. Digital Wrench will guide the technician through the
process for setting the TPS idle voltage. This procedure should only be performed if the TPS idle voltage setting is
incorrect, or when minor adjustments to the engine idle speed are desired.
Minor adjustments to the engine idle speed may be desired if the engine idle is too low or too high due to extreme external
environmental factors such as altitude. In addition to environmental factors, normal throttle body component wear and
tear may cause changes in idle speed over the life of the vehicle. The idle speed screw can be adjusted to compensate
for these changes.
IMPORTANT: Never set the TPS idle voltage below or above the specified voltage range. Setting the idle voltage
at the low end of the range will result in a lower idle speed. Setting the idle voltage at the upper end of the scale
will result in a higher idle speed.
Always check engine idle speed when the engine is at operating temperature and the idle speed has stabilized.
Engine idle speed with the engine at operating temperature is 1700 +/- 200 RPM.
600/800 DC-CFI
Engine Idle Speed
(Engine at operating temperature)
1700 +/- 200 RPM
NOTE: Test vehicle after performing the idle setting procedure to verify proper vehicle operation.

BASE AND IDLE SETTING
CAUTION
The throttle position sensor (TPS) is set at the time of throttle body manufacture. TPS adjustments should only be
made if the TPS was loosened, repositioned, or replaced.
Any adjustments made to the idle air gap screw, TPS sensor, or throttle synchronization screw should only be
performed when directed to so by the Digital Wrench Diagnostic Software.
Access the Base and Idle Setting procedure when repairing a loose TPS sensor, or when replacing the sensor with a 4
new part.
NOTE: New throttle body service parts include the TPS sensor and are set at the time of manufacture. Do not
perform the Base and Idle Setting procedure.
Digital Wrench will guide the technician through the process of establishing the TPS baseline voltage and TPS idle
voltage settings.
NOTE: Test vehicle after performing repairing/replacing TPS sensor and after completing base and idle
setting procedure to verify proper vehicle operation.
FULL PROCEDURE (Synchronization)
CAUTION
Severe engine damage may occur if the throttle plate synchronization is tampered with or set incorrectly. Read and
understand the instructions outlined in Digital Wrench when performing this procedure.
Access the Full Procedure (Sync) procedure only when it is known the throttle body plate synchronization screw has been
tampered with and the throttle plates are out of synchronization.
Digital Wrench will guide the technician through the process of establishing the correct synchronization between the MAG
and PTO throttle plates, setting the TPS baseline voltage, and setting the TPS idle voltage.
IMPORTANT: If the technician cannot confirm the throttle plate synchronization is set correctly, throttle body
replacement is required.
NOTE: Test vehicle after performing the full procedure (synchronization) procedure to verify proper vehicle
operation.

4.47
VARIABLE EXHAUST SYSTEM (VES) When troubleshooting the variable exhaust system, follow
these guidelines:
Overview
Use the recommended oil. Polaris recommends
The Polaris VES system uses exhaust valves VES Gold Plus engine oil for maximum VES
(1 valve per cylinder) to control the exhaust port height. performance.
The valves are actuated by controlling cylinder pressure Never mix different brands of oil.
with a solenoid, bellows, and a series of vent hoses. Follow the recommended valve periodic
The solenoid is powered by 12 VDC and turned on and off maintenance schedule.
by the engine control unit (ECU). Do not use harsh abrasives or sharp tools when
cleaning the valves. Small abrasions and nicks
When the solenoid is powered (ON), the VES vent paths can create pockets of carbon formation.
are open allowing cylinder pressure to vent to
atmosphere, and the guillotine valves remain in the closed Replace rusted/corroded springs.
(down) position. Inspect the bellows and replace if distorted,
stretched, or torn.
When the solenoid is OFF, the vent path(s) are closed. Replace the housing gasket each time the housing
Cylinder gas pressure builds within the exhaust valve is removed from the cylinder. Do not modify the
housings beneath the bellows. Once the cylinder gas
gasket in anyway.
pressure pushing on the bellows overcomes the spring
pressure, the bellows will inflate, lifting the guillotine Inspect the vent hoses and fittings for leaks.
valves from the closed (down) position. Remove and apply thread sealant to fittings that
appear to be leaking oil/exhaust gases.
The ECU uses engine RPM and throttle position (TPS) as Verify all hose clamps are tight.
the primary variable exhaust system solenoid control
Use a Mity Vac hand pump to test the solenoid
signals. In general, the ECU will close the solenoid at
function. The solenoid must hold pressure and not
100% wide open throttle (WOT) at approximately 6500-
leak when not powered. The solenoid must vent
6900 RPM.
when powered with 12VDC.
CAUTION
Do not plug the vent hoses or tamper with solenoid.

Severe engine damage may occur.

ELECTRONIC REVERSE (PERC) NOTE: Maximum RPM in reverse is 6000 RPM.
Overview NOTE: If the engine stops running or is shut off

while in reverse. The engine will start in forward
The operation of the electronic reverse system is achieved gear.
by automatically reversing the engine rotation with a push
of a button. When in reverse, an indicator light will flash, FORWARD OPERATION
indicating the engine is in the reverse mode. The design
of the clutches are matched to the specifications that will 1. If unit was operated in reverse, ensure that the path
allow the backwards rotation of the engine to move the ahead is clear, and push an hold the reverse button
sled in reverse. To get back to forward is as easy as for 1 second and then release the button. The engine
pushing the button again. will now automatically change direction form reverse
to forward and the reverse light on the instrument
Operation panel will stop flashing.
NOTE: When servicing clutches, ensure that the

4
WARNING vehicle is in forward gear. If not damage to the
driven clutch may occur when removing the belt.
Reverse operation, even at low speeds, may cause
loss of control, resulting in serious injury or death. To
avoid loss of control, always:
LOOK BEHIND BEFORE AND WHILE BACKING.
AVOID SHARP TURNS.
SHIFT TO OR FROM REVERSE ONLY WHEN
STOPPED.
APPLY THROTTLE SLOWLY.
CAUTION
To avoid personal injury and/or engine damage, do not

operate the electric start or recoil while engine is
running.
1. Ensure that the vehicle is stopped and the engine is

warmed up and running at idle.
NOTE: The system will only engage in reverse if the

engine is below 4000 RPM. If engine is above 4000
RPM the system can not be activated.
2. Ensure that the path behind you is clear.

3. Push and hold the yellow reverse button on the left
hand control for 1 second and then release the button.
The reverse light on the instrument panel will flash
when engine is in reverse motion.
NOTE: The engine will automatically reduce RPM

and it will reverse the rotation of the engine when the
RPM is at the lowest RPM point.
4. Ensure that the path behind you is clear.

5. Slowly apply throttle until the sled starts to move in
reverse, and carefully direct the sled in the direction
that you want.

4.49
Altitude Setting Important Notes
If your engine is carbureted, you can adjust the elevation Max RPM for shifting into reverse = 4000 RPM
setting of the Polaris electric reverse control (PERC). If Max RPM for operating in reverse = 6000 RPM
your engine is a Cleanfire system, this is automatically Engine must first reach 900 RPM at start up before
done through the engine controller unit (ECU), and you do the reverse system can be used. The system
not need to do any setting. works between 900 and 4000 RPM.
At higher elevations over 6000 feet (1829m), the engine If the button is pushed above 4000 RPM the
requires a different ignition RPM setting to improve the system is bypassed and nothing will happen.
operation of the reverse system. Flashing light on the instrument panel indicates
that the system is in reverse. On carbureted units
To set the altitude settings:
a slow flash indicates that the system is set for low
1. With the engine running, push and hold the reverse elevation, and a fast flash indicates the system is
button for 5 - 6 seconds and then release the button. set up for high elevation. Push and hold the
2. The reverse light will flash rapidly on the instrument reverse button for longer than 5 seconds to toggle
panel. back and forth from high and low elevation
settings. On Cleanfire units this is automatically
3. You have now set the PERC system to the higher
done through the engine controller unit (ECU).
elevation setting.
Elevation above 6000 ft (1829m) requires a
4. To go back to the low elevation setting repeat step 1.
different timing curve to eliminate a kick-back
The reverse light will flash slowly indicating that the
effect.
system is now in the lower elevation setting.
If engine is shut off or dies in forward or reverse
NOTE: The elevation setting will be set in the gear, the engine when started will automatically be
memory (engine running or not) until it is changed. in forward gear.
When servicing clutches, ensure that the vehicle is
in the forward gear.
On DC-CFI models the PERC system will not
operate if the TPS is out of adjustment or the 5
tooth CPS signal is interrupted or broken.

TROUBLESHOOTING Poor Performance
Engine Will Not Start Fuel quality. Use recommended fuel (91 octane
minimum).
Is the key inserted in key switch and turned to Ethanol/Non-ethanol fuel resistor plug. Is the
RUN? correct fuel selector plug connected for the type of
Is the safety slap switch pulled up? fuel in the tank?
Is the throttle lever free play set to specification? Are the spark plugs fouled? Correct gap set?
Is there fuel in the fuel tank? Is the fuel pressure correct at idle and during
Is the fuel tank vent/vac. hose plugged or operation?
malfunctioning? Remove fuel tank cap and try to Fuel filter. Has the fuel filter been serviced as part
start engine. of periodic maintenance?
Are the spark plugs fouled? Replace with new VES system. Have the valves, and bases been
spark plugs.
Is there spark at the spark plugs? Test with spark
serviced/cleaned as part of periodic maintenance?
VES system. Are the hoses loose, damaged or
4
plug tester. plugged/frozen?
Inspect wire harness connectors. Are connectors Inspect fuel injector power. Are injectors receiving
disconnected? Are there any broken wires? 16 VDC during operation?
Is the throttle plate gap set to specification? Is the engine mechanically sound? Perform a
Is there fuel pressure? Test using fuel pressure compression check on both cylinders. Are the
gauge. Determine if fuel filter requires results within 10% of each other?
replacement. Inspect piston skirts through exhaust ports. Is
Inspect the stator using multitester and/or Digital there any scuffing, ring damage, etc.?
Wrench. Are the fuel injectors receiving 16 VDC? Inspect the exhaust system. Are there any leaks,
Is the fuel pump receiving VDC power when missing springs, or damaged exhaust seals?
pulling recoil? Driveline. Inspect the driveline for damage. Set the
Are there any diagnostic trouble codes? Use track tension to specification. Is the track too tight
Digital Wrench to view trouble codes and perform or missing lugs? Is the gear ratio correct for
guided diagnostics. desired riding style?
Is the engine mechanically sound? Check cylinder Inspect the drive, driven clutches, and drive belt.
compression, piston condition, etc. Replace worn or damaged parts. Clean clutch
sheaves, and set belt deflection.
Engine Starts - Wont Idle/Stalls Are there any diagnostic trouble codes (DTCs).
Use Digital Wrench to retrieve any codes.
Is the throttle lever free play set to specification? Reference CFI Troubleshooting Flowchart
is the fuel tank vent/vac. hose plugged or Is detonation occurring and/or detonation engine
malfunctioning? Remove fuel tank cap and test. RPM limit occurring? Reference Detonation
Are the spark plugs fouled? Replace with new Troubleshooting Flowchart/checklist.
spark plugs.
Inspect wire harness connectors. Are connectors
disconnected? Are there any broken wires?
Is there fuel pressure? Test using fuel pressure
gauge. Determine if fuel filter requires
replacement.
Are there any diagnostic trouble codes? Use
Digital Wrench to view trouble codes and perform
guided diagnostics.
Is the throttle plate gap/TPS set to specification?

4.51
DC-CFI Troubleshooting Flowchart
Reference the following flowchart for general DC-CFI
troubleshooting techniques.
STEP 1 DOCUMENT THE BASICS

Preliminary 1. VIN
Checks 2. Vehicle Miles
3. Issue(s)
4. Vehicle / Engine Modifications (Non-approved modifications may cause performance/durability issues.)
5. Check unit against Unit Inquiry for any outstanding Service Bulletins or Team Tips
6. Type of fuel in the fuel tank / Fuel Selector Status
The fuel selector jumper wires or resistor plug must be set as outlined below based off of the type of fuel in the tank.
Fuel octane not known, < 91+ octane, or any 87+ octane oxygenated (ethanol, MTBE, etc, blended) fuel = 24 OHM Resistor
91+ octane non-oxygenated (non-ethanol) fuel = 160 OHM Resistor
STEP 2 DIGITAL WRENCH (DW)

Using 1. Is DW the most current version? Check the DW update site (http://polaris.diagsys.com/modules.php?name=Downloads) to review and
Digital download any available updates.
Wrench 2. Connect DW to the vehicle. Are there any trouble code(s)? Document all of the trouble code(s), both historic and current. Use guided
diagnostics to troubleshoot current trouble code(s). Once repairs are made and trouble code(s) are cleared, do any return? Start the
engine and confirm trouble code(s) to not re-appear. If trouble code(s) re-appear, continue to troubleshoot issue using guided
diagnostics and Service Manual.
3. Review the ECU information for the vehicle. Does the ECU map match the vehicles configuration / fuel injector color and part
number? If not, reflash the ECU using the correct color-coded map / part number that matches the fuel injector color / part number
installed on the engine.
4. Is the vehicle subject to any Service Bulletins, or Team Tips where revised ECU reflash files have been made available? If so, verify
the Service Bulletin or Team Tip has been performed if required and the ECU information matches the revised reflash files.
STEP 3 CLUTCHING
Clutching 1. Do the drive clutch weights match what is specified for the elevation where the vehicle is operated? If not, install the specified drive
clutch weights based model specifications for the vehicle located in the appropriate Service Manual or Owners Manual Supplement.
2. Inspect drive belt deflection and adjust if required. Replace the belt if it is hour-glassed, shows heavy glazing or severely worn.
THROTTLE LEVER FREEPLAY

STEP 4 1. Check the throttle lever freeplay. Too much slack in the throttle cable can cause runability issues.
Throttle Lever 2. Is the throttle lever freeplay = .010 - .030 inches? If not, reset the freeplay to specification and retest vehicle.
STEP 5 FUEL SYSTEM

Fuel 1. Using Digital Wrench, verify the fuel injector supply voltage is 16VDC when the engine is running.
System 2. Using the appropriate fuel pressure gauge (see Service Manual), verify the fuel pressure when the engine is running is 58 PSI (4BAR).
3. If the fuel pump voltage is good, but the fuel pressure low, replace the fuel filter and recheck fuel pressure.
STEP 6 EXHAUST GAS TEMPERATURE SENSOR

EGT 1. Using the data display tool in Digital Wrench, monitor the EGT sensor function while the engine is running (vehicle raised off the
Sensor ground on a sled lift or track stand) at or above 3,000 RPM.
2. Does the exhaust gas temperature value change with changing throttle lever input after running the engine for 60 seconds at or
above 3,000 RPM?
3. If the EGT value does not change, inspect the sensor wiring and connections. If the wiring and connections are good, replace the
sensor and retest.
STEP 7 EXHAUST SYSTEM

Exhaust 1. Check exhaust system for leaks, missing, over-stretched damaged springs, and worn out seals. Replace components as required.
System 2. Remove the resonator and shake. Replace resonator if shaking reveals loose internal baffle plates.
STEP 8 IGNITION SYSTEM

Ignition 1. Insect the spark plug caps and spark plugs. Are the caps worn, oblong, or bent? Replace cap(s) as required.
System 2. Have the spark plug(s) worn into the top of the cap(s)? If so, replace both the affected spark plug and cap as required.
STEP 9 EXHAUST VALVES

Exhaust 1. Inspect VES system. Clean valve blades as outlined in the periodic maintenance table. Inspect valve bellows for tears, damage.
Valves 2. Inspect the exhaust valve solenoid vent system (discharge hose) for leaks or plugged / kinked hoses. Repair or re-route hoses /
connections as required. Verify outlet hoses is not freezing during operation. Inspect fittings at solenoid are not leaking.
3. Do the exhaust valves move as RPM increases? Test exhaust valve motion by installing a 1 inch piece of clear, fuel vent hose onto
each EV cap nut through the hole in each EV housing. Start the engine and increase the engine speed past 6,000 RPM to check for
proper valve operation.
4. Do both valves move at the same time / rate? If not, inspect one or both EV assemblies. Inspect for torn bellows, worn EV springs
and loose bellows cap nuts. Verify the EV base vent and cylinder holes are clean and free from carbon or heavy residue.
PISTONS
STEP 10 1. With the exhaust valve assemblies removed from the cylinders, insert a piston wash light or use a flashlight to inspect the exhaust-
Pistons side of the pistons. Is heavy scoring, scratching or ring damage visible?
2. If piston skirt, or ring damage is visible through the exhaust valve slots, the pistons should be replaced and the cylinders inspected
and lightly honed with an Ammco 320 grit (or equivalent) NiCaSil oversize honing stone.
STEP 11 ENGINE
Engine 1. Perform compression test.
2. Inspect crankshaft index.
3. Verify flywheel key has not sheared (flywheel out of index).

Detonation Limit Troubleshooting Flowchart consistently enables the detonation dET engine
protection 6,500 RPM limiter.
Reference the troubleshooting table at the beginning of
the chapter and the following flowchart if the ECU
STEP 1 DOCUMENT THE BASICS

Preliminary 1. VIN
Checks 2. Vehicle Miles
3. Issue(s)
4. Vehicle / Engine Modifications (Non-approved engine/vehicle modifications may cause detonation.)
5. Check unit against Unit Inquiry for any outstanding Service Bulletins or Team Tips
6. Type of fuel in the fuel tank / Fuel Selector Status
The fuel selector resistor plug must be set as outlined below based off of the type of fuel in the tank.
Fuel octane not known, < 91+ octane, or any 87+ octane oxygenated (ethanol, MTBE, etc, blended) fuel = 24 OHM Resistor
91+ octane non-oxygenated (non-ethanol) fuel = 160 OHM Resistor
STEP 2 DIGITAL WRENCH (DW)

Using
Digital
Wrench
1. Is DW the most current version? Check the DW update site (http://polaris.diagsys.com/modules.php?name=Downloads) to review and
download any available updates.
2. Connect DW to the vehicle. Are there any trouble code(s)? Document all of the trouble code(s), both historic and current. Use guided
4
diagnostics to troubleshoot current trouble code(s). Once repairs are made and trouble code(s) are cleared, do any return? Start the
engine and confirm trouble code(s) to not re-appear. If trouble code(s) re-appear, continue to troubleshoot issue using guided
diagnostics and Service Manual.
3. Review the ECU information for the vehicle. Does the ECU map match the vehicles configuration / fuel injector color and part
number? If not, reflash the ECU using the correct color-coded map / part number that matches the fuel injector color / part number
installed on the engine.
4. Is the vehicle subject to any Service Bulletins, or Team Tips where revised ECU reflash files have been made available? If so, verify
the Service Bulletin or Team Tip has been performed if required and the ECU information matches the revised reflash files.
STEP 3 FUEL SYSTEM

Fuel 1. Check the fuel level in the tank.
System 2. Using Digital Wrench, verify the fuel injector supply voltage is 16VDC when the engine is running and while operating the snowmobile.
3. Using the appropriate fuel pressure gauge (see Service Manual), verify the fuel pressure when the engine is running and while
operating the snowmobile is 58 PSI (4BAR).
4. Verify fuel filter has been replaced as outlined in the periodic maintenance table. If it has not been replaced initially at 1,000 miles, and
then at 2,000 mile intervals, replace the fuel filter. Re-check fuel pressure.
STEP 4 EXHAUST VALVES

Exhaust 1. Inspect the exhaust valve solenoid vent system (discharge hoses) for leaks, plugged, kinked hoses, or icing. Repair or re-route hoses /
Valves connections as required. Verify the outlet hose is not freezing during operation.
2. Start the engine in a well-ventilated area. Raise the track off the ground with a track stand. Rev the engine to clutch engagement
speed. Inspect the VES solenoid outlet hose for exhaust gas discharge. If no gas discharge is seen, the hoses may be plugged,
restricted, or the solenoid circuit is damaged.
3. Do the exhaust valves move as RPM increases? Test exhaust valve motion by installing a 1 inch piece of clear, fuel vent hose onto
each EV cap nut through the hole in each EV housing. Start the engine and increase the engine speed past 6,000 RPM to check for
proper valve operation.
4. Do both valves move at the same time / rate? If not, inspect one or both EV assemblies. Inspect for torn bellows, worn EV springs
and loose bellows cap nuts. Verify the EV base vent and cylinder holes are clean and free from carbon or heavy residue.
STEP 5 DETONATION SENSOR FASTENER TORQUE

Detonation Sensor 1. The DET sensor fastener must be installed clean and dry and torqued to specification: (168 in.lbs./19 Nm).
Fastener Torque
AIR LEAKS
STEP 6 1. Check air box seals, foam, mounting boots, air box-to-hood interface. Verify air box assembly is not cracked/damaged.
Air Leaks 2. Inspect throttle body boots for delaminating rubber, or if boots are torn. Verify boots are seated correctly against air box and
throttle body.
3. Does snowmobile have an aftermarket air intake kit installed? Remove the kit and reinstall original components.
4. Inspect engine crankcase seals/base gaskets, etc. for leaks.
EXHAUST GAS TEMPERATURE SENSOR
STEP 7 1. Using the data display tool in Digital Wrench, monitor the EGT sensor function while the engine is running (vehicle raised off the
EGT 4
STEP ground on a sled lift or track stand) at or above 3,000 RPM.
Sensor
Clutching 2. Does the exhaust gas temperature value change with changing throttle lever input after running the engine for 60 seconds at or
above 3,000 RPM?
3. If the EGT value does not change, inspect the sensor wiring and connections. If the wiring and connections are good, replace the
sensor and retest.
EXHAUST SYSTEM
STEP 8
1. Remove aftermarket exhaust pipe(s) and/or non-Polaris tested silencer.
Exhaust
2. Check exhaust system for leaks, missing, over-stretched damaged springs, and worn out seals. Replace components as required.
System
3. Remove the resonator and shake. Replace resonator if shaking reveals loose internal baffle plates.

4.53
NOTES

Final Drive/Brake System
CHAPTER 5
TRACK STUD SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.2
TRACK STUDDING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.2
DRIVE GEARS/CHAINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.3
DRIVE GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3
DRIVE CHAINS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.3
GEAR RATIO SPEED CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.4
7.53 CD CHAINCASE SPEED CHART. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.4
CHAINCASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.5
SPECIFICATIONS/TORQUE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.5
CHAINCASE COVER TORQUE PATTERN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.5
BRAKE CALIPER TYPES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.5
FULL ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.6
5
CHAINCASE DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.7
CHAINCASE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.8
MOUNTING ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.10
NON-BONDED CHAINCASE REMOVAL/INSTALLATION. . . . . . . . . . . . . . . . . . . . . . .5.10
BONDED CHAINCASE REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . .5.11
DRIVESHAFT/JACKSHAFT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.12
SPECIFICATIONS/TORQUE GUIDE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.12
ASSEMBLY VIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.12
JACKSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.13
JACKSHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.13
DRIVESHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.13
DRIVESHAFT INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.13
BRAKE SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5.14
GENERAL GUIDELINES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.14
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.15
COMPENSATING PORT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.15
BRAKE FLUID REPLACEMENT & BLEEDING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.16
COMBINED MASTER CYLINDER/LEVER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . .5.17
CYCLONE MASTER CYLINDER/LEVER SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . .5.17
BRAKE LINE REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.17
BRAKE HOSE ROUTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.18
COMBINED MC BRAKE LIGHT SWITCH REPLACEMENT. . . . . . . . . . . . . . . . . . . . . .5.19
PHANTOM BRAKE CALIPER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.19
PHANTOM BRAKE CALIPER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.19
PHANTOM BRAKE CALIPER PISTON AND SEAL REPLACEMENT . . . . . . . . . . . . . .5.20
PHANTOM BRAKE PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.21
PHANTOM LITE BRAKE CALIPER BRACKET/SEAL/PISTON SERVICE . . . . . . . . . . .5.21
PHANTOM LITE BRAKE PAD REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.23
BRAKE DISC REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .5.24

5.1
TRACK STUD SPECIFICATIONS Stud templates are guides designed to locate where to drill
the track when installing studs depending on the track
Track Studding length, desired number of studs, and pattern.
2.86 Pitch Track Template: 2878247

CAUTION 2.52 Pitch Track Template: 2875157
Do not install stud lengths that are not recommended in The 1.25 Ripsaw track used on 2010 Rush snowmobiles
the guidelines. Severe track and/or tunnel damage may feature stud location indicators molded into the outer
occur. cover of the track. The indicators mark the manufacture-
recommended stud pattern for improved performance and
General Studding Guide Lines:
maximum track durability.
Optimal stud penetration range is .250"-.375"
(6.35-9.52mm).
DO NOT EXCEED .375" (9.52mm) STUD

PENETRATION ON ANY TRACK.
2010-2011 Rush Maximum Track Lug Height

WITHOUT Studs = 1.5." DO NOT INSTALL
STUDS ON A 1.5" TRACK.
2012 Rush/Switchback Maximum Track Lug

Height WITHOUT Studs = 2.0". DO NOT INSTALL
STUDS ON A 2.0" TRACK.
2012 Rush/Switchback Maximum Track Lug WITH

STUDS = 1.75". DO NOT EXCEED .375" STUD
PENETRATION ON A 1.75" TRACK.
Switchback Assault 1.3 Maximum Stud Length =

1.325" when using Woodys Studs.
DO NOT INSTALL STUDS ON A 2.0"+ TRACK.
Studs can be installed on the inner and outer track

rows. Studding the inside of the track is good for
improving traction and vehicle braking. Adding
studs to the outer rows is generally considered for
drivers who desire a high degree of traction, but STUD LOCATION INDICATORS
can sacrifice track durability. Studs placed on the
outer rows are more susceptible to being ripped
out of the track.
Adding studs may require the use of longer, more

aggressive ski wear bars/carbides.
A wear strip kit must be installed to protect the

tunnel and tunnel cooler when studs are installed.
2010-2011 Rush Wear Strip Kit PN: 2878532

Switchback Assault 1.3 PN: 2878161
2012 Rush/Switchback: Integrated
Consult stud manufacture for more information

and recommendations.

DRIVE GEARS/CHAINS
Drive Gears
PART NUMBER DESCRIPTION

3221095 19T, 3/4W, 15 SPL, HYVO, PM
3221096 20T, 3/4W, 15 SPL, HYVO, PM
3221097 21T, 3/4W, 15 SPL, HYVO, PM
3221098 22T, 3/4W, 15 SPL, HYVO, PM
3221099 23T, 3/4W, 15 SPL, HYVO, PM
3221101 24T, 3/4W, 15 SPL, HYVO, PM
3221102 25T, 3/4W, 15 SPL, HYVO, PM
3222127 26T, 3/4W, 15 SPL, HYVO, PM
3222126
3222125
36T, 3/4W, 15 SPL, HYVO, PM
37T, 3/4W, 15 SPL, HYVO PM
5
3222108 39T, 3/4W, 15 SPL, HYVO, PM
3222099 40T, 3/4W, 15 SPL, HYVO, PM
3222101 41T, 3/4W, 15 SPL, HYVO, PM
3221188 43T, 3/4W, 15 SPL, HYVO, PM
Commercially
Available
3222146 45T, 3/4W, 15 SPL, HYVO, PM
Commercially
Available
Drive Chains

3221112 68P, 3/4W, HYVO CHAIN
3221115 70P, 3/4W, HYVO CHAIN
3221110 72P, 3/4W, HYVO CHAIN
3221109 74P, 3/4W, HYVO CHAIN
3221108 76P, 3/4W, HYVO CHAIN

5.3
GEAR RATIO SPEED CHART chaincase. MPH speed is the theoretical speed when the
drive and driven clutches are at a 1:1 ratio.
The following gear and chain combinations are
acceptable for use with the 7.53 center distance
7.53 CD Chaincase Speed Chart

ENGINE RPM
8250 8000 7750 7500 7250 7000 6750 6500 6250 6000
TOP GEAR BOTTOM GEAR CHAIN PITCH RATIO MPH AT 1:1 DRIVE RATIO
26 36 72 1.38 129 125 121 117 113 110 106 102 98 94
26 37 72 1.42 126 122 118 114 110 107 103 99 95 91
25 37 72 1.48 121 117 113 110 106 102 99 95 91 88
25 38 72 1.52 118 114 110 107 103 100 96 93 89 86
26 40 74 1.54 116 113 109 106 102 99 95 92 88 85
23 36 70 1.57 114 111 107 104 100 97 93 90 87 83
26 41 74 1.58 113 110 106 103 100 96 93 89 86 82
24 38 72 1.58 113 109 106 103 99 96 92 89 86 82
25 40 74 1.60 112 108 105 102 98 95 91 88 85 81
25 40 74 1.60 112 108 105 102 98 95 91 88 85 81
24 39 72 1.63 110 107 103 100 97 93 90 87 83 80
22 36 70 1.64 109 106 103 99 96 93 89 86 83 79
25 41 74 1.64 109 106 102 99 96 92 89 86 83 79
25 41 74 1.64 109 106 102 99 96 92 89 86 83 79
23 38 72 1.65 108 105 102 98 95 92 89 85 82 79
26 43 76 1.65 108 105 102 98 95 92 88 85 82 79
26 43 76 1.65 108 105 102 98 95 92 88 85 82 79
25 42 74 1.68 106 103 100 97 94 90 87 84 81 77
22 37 70 1.68 106 103 100 97 93 90 87 84 81 77
26 44 76 1.69 106 102 99 96 93 90 86 83 80 77
23 39 72 1.70 105 102 99 96 93 89 86 83 80 77
24 41 74 1.71 105 101 98 95 92 89 86 82 79 76
24 41 74 1.71 105 101 98 95 92 89 86 82 79 76
21 36 70 1.71 104 101 98 95 92 88 85 82 79 76
23 40 72 1.74 103 100 97 93 90 87 84 81 78 75
24 42 74 1.75 102 99 96 93 90 87 84 80 77 74
24 42 74 1.75 102 99 96 93 90 87 84 80 77 74
25 44 76 1.76 102 98 95 92 89 86 83 80 77 74
25 44 76 1.76 102 98 95 92 89 86 83 80 77 74
21 37 70 1.76 101 98 95 92 89 86 83 80 77 74
22 39 72 1.77 101 98 95 92 89 86 83 79 76 73
22 39 72 1.77 101 98 95 92 89 86 83 79 76 73
25 45 76 1.80 99 96 93 90 87 84 81 78 75 72
21 38 70 1.81 99 96 93 90 87 84 81 78 75 72
22 40 72 1.82 98 95 92 89 86 83 80 77 74 72
23 42 74 1.83 98 95 92 89 86 83 80 77 74 71
23 42 74 1.83 98 95 92 89 86 83 80 77 74 71
19 35 68 1.84 97 94 91 88 85 82 79 76 74 71
20 37 70 1.85 97 94 91 88 85 82 79 76 73 70
23 43 74 1.87 96 93 90 87 84 81 78 75 72 70
24 45 76 1.88 95 92 90 87 84 81 78 75 72 69
20 38 70 1.90 94 91 88 86 83 80 77 74 71 68
21 40 72 1.90 94 91 88 85 82 80 77 74 71 68
24 46 76 1.92 93 90 88 85 82 79 76 73 71 68
21 41 72 1.95 92 89 86 83 80 78 75 72 69 67
22 43 74 1.95 91 89 86 83 80 78 75 72 69 67
19 38 70 2.00 89 87 84 81 79 76 73 70 68 65
22 44 74 2.00 89 87 84 81 79 76 73 70 68 65
23 46 76 2.00 89 87 84 81 79 76 73 70 68 65
20 41 72 2.05 87 85 82 79 77 74 71 69 66 63
20 41 72 2.05 87 85 82 79 77 74 71 69 66 63
19 39 70 2.05 87 84 82 79 77 74 71 69 66 63
21 44 74 2.10 85 83 80 78 75 72 70 67 65 62
20 42 72 2.10 85 83 80 77 75 72 70 67 64 62
21 45 74 2.14 83 81 78 76 73 71 68 66 63 61
19 42 72 2.21 81 78 76 74 71 69 66 64 61 59
20 45 74 2.25 79 77 75 72 70 67 65 63 60 58
19 43 72 2.26 79 77 74 72 69 67 65 62 60 57
19 45 74 2.37 75 73 71 69 66 64 62 59 57 55
19 46 74 2.42 74 72 69 67 65 63 60 58 56 54

CHAINCASE Brake Caliper Types
Phantom
Specifications/Torque Guide
-Fixed Caliper, Dual Floating Pistons
COMPONENT TORQUE/SPEC.
Lubricant Polaris 80W SCL

Capacity 9oz. (266 ml)
Cover Fasteners
9.5 ft-lb (13 Nm)
(Follow Torque Pattern)
Chain Tensioner Jam Nut 21 ft-lb (28 Nm)
Fill Plug 6 - 9.5 ft-lb (8 - 13 Nm)
Drain Plug
(Clean socket prior to inserting 6 - 9.5 ft-lb (8 - 13 Nm)
tool.)
Brake Disc Fastener
2010
2011-Current
29 ft-lb (40 Nm)
40 ft-lb (54 Nm) 5
Lower Gear Fastener 29 ft-lb (40 Nm)
Brake Caliper Mounting
40 ft-lb (54 Nm)
Fasteners
Chaincase Cover Torque Pattern

Phantom Lite
-Floating Caliper, Single Piston
1
4

5.5
Full Assembly View
18
21
16
17
20
14
21
15
12
15 13
10
19
20 14 22
19
7
6
12
5
11 4
9
8 2 1
3 23
23 24
2
1
REFERENCE # DESCRIPTION REFERENCE # DESCRIPTION
1 Brake Disc Fastener 14 Snap Rings

Phantom Caliper Models = Flat Washer 15 Bearings
2 Phantom Lite Caliper Models = Domed
16 Chain Tensioner/Wear Pad
(Beveled) Washer
17 Tensioner Adjustment Screw/Jam Nut
3 Brake Disc
18 Vent
4 Seal Sleeve
19 Fill/Drain Plugs
5 Jackshaft O-Ring
20 Alignment Dowels
6 Seal
21 Seals
7 Bearing
22 Dome (Beveled) Washer
8 Cover Fasteners
Float Washer
9 Cover
2010 = (To get .8mm disc float = 1-2 QTY.)
23
10 Chaincase Sleeve 2011-Current= (1 QTY.)
Phantom Lite Brake Caliper = (1 QTY.)
11 Cover Gasket
Wave Washer
12 Top/Bottom Gears 24
2011-Current Phantom Caliper Models
13 Chain

Chaincase Disassembly 9. Remove the brake disc from the jackshaft. Reference
table for brake disc hardware.
screw securing the right lower fender to the chassis.
YEAR/
2. Remove the hood assembly. BRAKE DISC FASTENER HARDWARE
CALIPER TYPE
3. Remove the exhaust silencer.
4. If equipped with electric start, remove the battery and Fastener: 29 ft-lb (40 Nm)
battery box. 2010/ Flat Washer
Phantom 1-2 Float Washers
(Install QTY. to achieve .8mm Disc Float)
CAUTION
Fastener: 40 ft-lb (54 Nm)
2011-Current/ Flat Washer
Remove the RED (+) battery cable first, and then the
Phantom Wave Washer
BLACK (-) cable last. Reverse order when attaching 1 Float Washer
cables to battery.
2011-Current/ Fastener: 40 ft-lb (54 Nm)
5. Place a drain pan under the chaincase. Remove the Phantom Lite Domed (Beveled) Washer (Dome facing out.)
plug to drain the oil. Clean the plug threads. Verify the
o-ring is not damaged.
6. Reinstall plug and torque to specification. 5
=T
Chaincase Drain Plug: 8-9.5 ft-lb (8-13 Nm)
7. Apply the parking brake and then loosen the brake

disc mounting fastener.
8. Release the parking brake. Remove the brake calliper See Table
mounting bolts. Tie the caliper to overstructure.
NOTE: DC-CFI-2 models with Phantom brake calipers

have washers in place of silencer bracket. Phantom
Lite models do not use washers or bracket. 10. Note the groove on the seal sleeve. Use a pair of flat
blade screwdrivers or soft-jawed pliers to carefully pry
SILENCER BRACKET
BRAKE CALIPER the sleeve out of the cover.
11. Locate the o-ring on the end of the jackshaft inside the
cover. Use a pick and carefully remove the o-ring.
Inspect o-ring and discard if damaged or torn.
O-RING
CAUTION O-RING
Do not allow the brake caliper to hang by the brake hose.

5.7
18. Loosen the chain adjuster screw. Remove the
tensioner pad, upper and lower gears, and chain.
GEARS/CHAIN
O-RING
SEAL SLEEVE
12. Remove the cover fasteners. Chaincase Assembly

13. Carefully remove the cover. Use a flat blade
1. Thoroughly clean the chaincase, gears, and chain.
screwdriver at the pry points to aid removal.
2. Inspect the tensioner pad for damage. Replace if
PRY POINT excessive wear is evident.
3. Install the gears and chain as a set.
4. Install the lower gear screw and beveled washer.
Verify the beveled washer is installed dome side out.
5. Torque screw to specification.
=T
PRY POINT Lower Gear Fastener: 29 ft-lb (40 Nm)
COVER
6. Rotate the driven clutch forward to move all of the

14. After removing the cover, note the two dowels in the
chain slack to the tensioner side.
chaincase.
7. Install the chain tensioner. Tighten the tensioner
15. Inspect the cover gasket for damage. Inspect the
screw until there is 1/8" (3.175mm) chain deflection on
bearing and seal in the cover. Replace bearing if it no
the backside of the drive chain.
longer rolls smoothly. Replace the seal if damaged.
8. Verify the tensioner screw washer is seated against
16. Remove the chaincase sleeve from the jackshaft.
the chaincase, and then torque the tensioner screw
jam nut to specification.
DOWEL =T
Tensioner Jam Nut: 21 ft-lb (28 Nm)
SLEEVE
9. Install the chaincase sleeve on to the jackshaft.
10. Inspect the cover gasket. Replace if cut or torn. Verify
the gasket is installed flush in the cover.
TENSIONER ADJUSTER 11. Install the cover making sure the cover engages the
two dowels evenly.
DOWEL 12. Lightly tap on the cover with a soft-faced hammer to
seat the cover.
17. Remove the lower gear screw. Note the beveled
washer orientation.

13. Install the cover screws. Torque screws to 20. Install the exhaust silencer. Verify the outlet boot is
specification using the specified sequence. See installed correctly around the silencer outlet tube.
Chaincase Cover Torque Pattern on page 5.5. 21. Install the screw securing the right fender to the
chassis. Reinstall the hood assembly and both door
=T panels.
22. Refill the chaincase with synthetic 80W lubricant. Fill
Cover Fasteners: 9.5 ft-lb (13 Nm) to specification or when lubricant reaches the fill plug
bore opening.
14. Install the o-ring on to the jackshaft. Verify the o-ring
is sitting in the groove. Install the seal sleeve with the
groove facing out.
15. Clean the brake disc with brake cleaner and then
install on to jackshaft.
16. Install the specified brake disc hardware as shown in
the table.
YEAR/
CALIPER TYPE
BRAKE DISC FASTENER HARDWARE
5
2010/ Flat Washer
Phantom 1-2 Float Washers
Phantom Wave Washer
1 Float Washer
Phantom Lite Domed Washer (Dome facing out.)
17. Install the brake caliper and silencer bracket if

equipped. Torque fasteners to specification.
=T
Brake Caliper Fasteners: 40 ft-lb (54 Nm)
18. Set the parking brake. Torque the brake disc screw to
specification. Release the parking brake.
=T
Brake Disc Fastener:
2010: 29 ft-lb (40 Nm)
2011-Current: 40 ft-lb (54 Nm)
19. If equipped with electric start, reinstall the battery box,

and battery. Connect the BLACK (-) first, and then the
RED (+) battery cable.

5.9
Mounting Assembly View
Stud Plate-RMK Models Only

Tunnel Reinforcement Plate-Switchback Only
C
3
Align with bulkhead cooler.
4 3 C 1
A
3 C
B
3
C
NOTE: 2012 Pro-Ride models feature a bonded 3. Remove the fasteners securing the chaincase to the
chaincase. tunnel, front cooler/closeoff panel, and side support.
4. Inspect the seals for excessive wear or damage.
REFERENCE # DESCRIPTION Replace as required.
5. Verify bearings roll smoothly. Replace if they do not
1 Screw-M8x1.25x35.8 or if excessive play is evident. Use an arbor press to
2 Screw - M8x1.25x30.8 remove and install bearings.
3 Carriage Bolts-M6x1.0x20 6. To install the chaincase, loosely install all of the
fasteners using new lock nuts where applicable.
Stud Plate (RMK models only)
7. Verify fastener (1) is installed in the lower chaincase
4 Reinforcement Plate (Switchback only-not
mounting hole has shown in the illustration.
shown.)
8. Torque fasteners to specifications.
CAUTION =T
Do not re-use lock Nuts. Always replace with new parts A: 26 ft-lb (35 Nm) DO NOT OVER-TORQUE
after removal. B: 26 ft-lb (35 Nm)
C: 14 ft-lb (19 Nm)
Non-Bonded Chaincase Removal/ 9. Follow the procedures for reinstalling the driveshaft
Installation and track.
1. Follow the procedures for chaincase disassembly. 10. Follow the procedures for chaincase assembly.
2. Follow the procedures for removing the track and
driveshaft.

Bonded Chaincase Removal/Installation
1. Follow the procedures for chaincase disassembly.
2. Follow the procedures for removing the track, rear
suspension, and driveshaft.
3. Remove the fasteners securing the chaincase to the
tunnel, front cooler/closeoff panel, and side support. ADHESIVE
LINE
4. While wearing protective gloves and clothing, use a
propane torch to evenly heat the backside and
fastener points of the chaincase/tunnel.
CAUTION
Keep flame away from flammable materials. Use

propane torch in well-ventilated area.
Only apply heat to area that requires adhesive bond

separation. Do not apply heat to areas of adhesive
where bond line separation is not needed. Doing so will 5
require removing the part, removing adhesive, and then
re-applying new adhesive.
ADHESIVE
5. While applying heat, carefully and slowly pull the LINE
chaincase assembly away from the tunnel. Use

extreme care as to not distort the tunnel.
10. Begin chaincase installation by verifying all fasteners
6. Allow the chaincase to properly cool. Once cooled,
are accounted for and staged for installation.
inspect the seals for excessive wear or damage.
Replace as required. 11. Verify the chaincase and tunnel mating surfaces are
clean and free of dirt, and oil residue.
7. Verify bearings roll smoothly. Replace if they do not
or if excessive play is evident. Use an arbor press to 12. Reference Adhesive Applicator Kit and Adhesive
remove and install bearings. Application sections in Chapter 9. See Bonded
Component Service on page 9.21.
8. Thoroughly clean the chaincase-to-tunnel mating
surfaces. All residual bonding adhesive MUST be
NOTE: The Bonded Component Service section in
removed. Use a putty knife and wire brush to remove
Chapter 9 outlines the adhesive, applicator tools, and
material.
the adhesive application procedure required to
9. After removing residual adhesive, wash parts in properly install bonded components.
solution of warm, soapy water and allow to air dry.
13. After the adhesive has been applied to the backside
of the chaincase, quickly install all of the fasteners.
14. Verify fastener (1) is installed in the lower chaincase
mounting hole has shown in the illustration. See
Mounting Assembly View on page 5.10.
15. Torque fasteners to specifications.
=T
A: 26 ft-lb (35 Nm) DO NOT OVER-TORQUE
B: 26 ft-lb (35 Nm)
C: 14 ft-lb (19 Nm)
16. Follow the procedures for reinstalling the driveshaft

and track.
17. Follow the procedures for chaincase assembly.

5.11
DRIVESHAFT/JACKSHAFT
Specifications/Torque Guide
COMPONENT TORQUE
Jackshaft Flange Nuts 18 ft-lb (25 Nm)

Speedometer Flange Nuts 18 ft-lb (25 Nm)
Driveshaft Flange Nuts 18 ft-lb (25 Nm)
Driven Clutch Fastener 18 ft-lb 25 Nm)
Speed Sensor Screw 18 ft-lb 25 Nm)
Assembly View
NUT PLATE-2011-CURRENT
1
5
3
NOTE: The PTO ends of the jackshaft/driveshaft

REFERENCE # DESCRIPTION
feature sealed bearings. No grease required.
6 Nut Pals
REFERENCE # DESCRIPTION
1 Flangette
CAUTION
2 Jackshaft
3 Driveshaft Do not re-use lock Nuts. Always replace with new parts
after removal.
4 Gasket
5 Speedometer Housing

Jackshaft Removal Driveshaft Installation
1. Follow the procedures for chaincase disassembly. 1. From underneath the tunnel, insert the flangette-side
2. Remove the driven clutch assembly. of the driveshaft through the bulkhead.
3. Remove the oil tank/clutch cover assembly. Remove 2. Once aligned with the chaincase, carefully insert the
the airbox. spline-end into the lower chaincase hole.
4. Remove the jackshaft flangette screws and nuts or nut 3. Verify the gasket is not damaged or torn.
plate. Discard the lock Nuts. 4. Using new lock nuts, loosely install both the driveshaft
5. Carefully pull the jackshaft from the clutch-side of the and speedometer flangette.
vehicle out of the chaincase. Remove jackshaft from 5. Torque the speedometer housing and driveshaft nuts
vehicle. to specifications.
Jackshaft Installation =T
1. Carefully insert the jackshaft through the bulkhead
and into the chaincase. Speedometer Housing/Driveshaft Nuts:
18 ft-lb (25 Nm)
2. Using new lock Nuts, install the jackshaft flangette.
Torque nuts to specification. 6. Install the driven clutch assembly. Torque driven
clutch fastener to specification. 5
=T
=T
Jackshaft Flange Nuts: 18 ft-lb (25 Nm)
Driven Clutch Fastener: 18 ft-lb (25 Nm)
3. Reinstall the airbox assembly and driven clutch.
torque driven clutch fastener to specification. 7. Reinstall the track/rear suspension.
8. Follow the procedures for chaincase assembly.
=T
NOTE: The driveshaft features a sealed bearing. No
Driven Clutch Fastener: 18 ft-lb (25 Nm) grease is required.
The speedometer sensor pickup gear is not
4. Follow the procedures for chaincase assembly. serviceable.
NOTE: The jackshaft features a sealed bearing. No

grease is required.
Driveshaft Removal
1. Follow the procedures for chaincase disassembly.
2. Remove the driven clutch assembly.
3. Remove the track/rear suspension from the vehicle.
4. Remove the nuts securing both the speedometer
housing to the chassis and the nuts securing the
driveshaft to the speedometer housing. Discard the
lock Nuts.
5. Carefully pull the driveshaft from the clutch-side of the
vehicle out of the chaincase. When the driveshaft
clears the chaincase, drop it down through the tunnel
and then remove the driveshaft from the vehicle.
6. Inspect the drive sprockets for damage and excessive
wear. Complete driveshaft replacement is required if
sprockets or bearing are damaged.
7. Inspect the gasket. Replace if worn or damaged.

5.13
BRAKE SYSTEM Keep these points in mind when bleeding hydraulic
brakes:
General Guidelines
The master cylinder reservoirs have limited
capacities. It is easy to empty them during the
WARNING bleeding procedure. This introduces air into the
system which you are trying to purge. Watch the
An unsafe condition exists when air is trapped in the reservoir closely and add fluid when necessary to
hydraulic brake system. Air in the brake hydraulic prevent air from entering the system.
system acts like a soft spring and absorbs a large Apply only light to moderate pressure to the lever
percentage of the pressure developed by the master or pedal when bleeding the brake system.
cylinder. Without this pressure, the braking system Extreme pressure will cause a surge of fluid
cannot develop full braking force to allow for safe, through the small orifices of the brake system
controlled stops. It is extremely important to bleed the when the bleeder screw is opened and introduce
brakes properly after any brake system work has been air into the system by means of cavitation.
performed or when inspection reveals spongy brakes.
Small amounts of air can become trapped in the
A soft, spongy feeling in the brake lever and/or brake banjo bolt fittings at the master cylinder(s) and
pedal could indicate a hazardous condition in the brake junction points of brake lines. These fittings can be
system. Do not operate the vehicle until the failure in purged of air by following a standard bleeding
the brake system is corrected. procedure at these fittings (instead of the bleed
screw on caliper) if necessary to speed the
Keep brake fluid tightly sealed and out of reach of bleeding process. This is usually only needed if
children. Brake fluid can accumulate moisture, system was completely drained of fluid. Bleed
reducing it's effectiveness. each line connection, starting with the fitting
closest to the master cylinder, working toward the
Contaminated brake discs or brake pads greatly caliper, and ending with the bleed screw.
reduce braking performance and increase stopping
distance. Do not attempt to clean contaminated pads. Always torque banjo bolts and other brake system
Replace them. Clean the brake disc with brake cleaner. fittings to specified torque.
This brake system requires ethylene-glycol based fluid Change fluid every 2 years, or when fluid is dark or
(DOT 4). Do not use or mix different types of fluid such contamination is suspected.
as silicone-based or petroleum-based.
Do not use brake fluid taken from old, used or unsealed

containers. Never reuse brake fluid.
CAUTION
Pressure bleeding is not recommended. When fluid

surges through the fittings, it is possible to cavitate the
fluid and create air in the system. In addition, the fluid
stored in a pressure bleeder may be contaminated. Al-
ways use fresh DOT 4 brake fluid from a sealed con-
tainer.

Overview
C
E
A B
The Polaris snowmobile hydraulic brake system consists fluid level mark on the inside of the reservoir, 1/4" - 5/16"
5
of the following components or assemblies: brake lever, (.6 -.8 cm) below lip of reservoir opening.
master cylinder, hydraulic hose, brake caliper (slave This system also incorporates a diaphragm (E) as part of
cylinder), brake pads, and a brake disc which is secured the cover gasket and a vent port (on cover) located
to the drive line. between the gasket and the cover. The combination
When the hand activated brake lever (A) is applied, it diaphragm and vent allow for the air above the fluid to
contacts a piston (B) within the master cylinder. As the equalize pressure as the fluid expands or contracts. Be
master cylinder piston moves inward it closes a small sure the vent is open and allowed to function. If the
opening called a compensating port (C) within the cylinder reservoir is overfilled or the diaphragm vent is plugged, the
and starts to build pressure within the brake system. As expanding fluid may build pressure in the brake system
the pressure within the system is increased, the pistons and lead to brake failure.
(D) located in the brake caliper move toward the disc and
applies pressure to the moveable brake pads. As the lever
pressure is increased, the braking effect is increased.
The friction applied to the brake pads will cause the pads
to wear. As the pads wear, the piston within the caliper self-
adjusts and moves further outward.
Brake fluid level is critical to proper system operation. A
low fluid level allows air to enter the system causing the
brakes to feel spongy.
Compensating Port
Located within the master cylinder is a small
compensating port (C) which is opened and closed by the
master cylinder piston assembly. The port is open when
the brake lever is released and the piston is outward. As
the temperature within the hydraulic system changes, this
port compensates for fluid expansion caused by heat, or
contraction caused by cooling. During system service, be
sure this port is open. Due to the high temperatures
created within the system during heavy braking, it is very
important that the master cylinder reservoir have
adequate space to allow for the brake fluid to expand.
Master cylinder reservoirs should be filled to the top of the

5.15
Brake Fluid Replacement & Bleeding 5. Fully apply the brake and hold, check for air bubbles
rising in the fluid, indicating that air is being forced out
Each hydraulic brake is fitted with a bleeder valve and a of the system.
banjo bolt. The bleeder valve is a special screw, which
6. Continue actuating the brake until air bubbles stop.
seals when tightened to the correct torque, but which
This indicates that the brake has been bled
allows air and/or fluid to pass out through a hole in the
successfully.
valve stem when loosened one turn.
NOTE: Add new fluid to the master cylinder reservoir
NOTE: A second person is usually needed to assist in as needed.
bleeding the brakes.
7. Retighten the bleeder valve when the brake lever has
1. Clean the master cylinder cover and remove. reached the end of its stroke. Torque bleeder to
specification.
=T
Brake Caliper Bleeder Screws:
Phantom: 100-135 in-lb (11-15Nm)
Phantom Lite: 36-46 in-lb (4-5Nm)
8. Evaluate the brake system for proper operation, and

inspect for leaks. The brake lever should feel firm,
without excessive travel and sponginess.
9. Add new fluid to the master cylinder reservoir to bring
the fluid level back up to a level between the maximum
and minimum fill lines. Replace master cylinder cover.
2. Attach one end of a flexible tube over the stem of the
bleeder valve.
=T
Master Cylinder Cover Screws:
Combined: 16-20 in-lb (1.8-2.3Nm)
Cyclone: 6-8 in-lb (.7-.9Nm)
CAUTION
Caution: Take care not to get brake fluid on pads or disc.

If brake fluid gets on disc, fully clean disc with alcohol.
10. Test brake system prior to returning vehicle to service.
NOTE: A 'box end' wrench placed on the bleeder

valve before attaching the flexible tubing is a
convenient method for loosening and tightening the
bleed valve.
3. Place the other end of flexible tube into a jar

containing a small amount of clean fluid. See that the
end of the tube is below the fluid surface to prevent
breathing/sucking air back into the system.
4. Loosen bleeder valve one turn.

Combined Master Cylinder/Lever Service Remove the parking brake lever.
COVER SCREWS
4. To remove the cartridge, completely drain the brake
fluid from the housing. Remove the brake and parking
brake levers.
COVER
5. Disconnect the brake hose from the cartridge.
Carefully pop the cartridge out of the housing.
6. To install the cartridge, lubricate the entire surface
with DOT 4 brake fluid.
PARKING BRAKE LEVER 7. Align the cartridge with the housing tabs, then firmly
press the cartridge back into the housing until the
LEVER PIN cartridge is engaged with the tabs.
8. Refill and bleed the brakes system as outlined in this
chapter. See Brake Fluid Replacement & Bleeding
SWITCH
on page 5.16.
Cyclone Master Cylinder/Lever Service
E CLIP
CARTRIDGE
5
BRAKE LEVER
COVER SCREWS CLAMP SCREWS
Swtich Pack Screw Location/Torque Sequence:

COVER
#10x.75 SCREWS CLAMP
LEVER PIN
BRAKE SWITCH
E CLIP
#10x1.12 SCREW BRAKE LEVER
#10x1.5 SCREW E CLIP

Torque upper two screws until gap is closed. TOP PARKING BRAKE LEVER
Torque bottom two screws to specification. 1 2
Test MODE/SET switch for binding.
If switch binds, loosen bottom two screws evenly 3 4
until binding stops. Maintain a closed gap at the top.
TORQUE SEQUENCE
=T
=T Cover Screws: 6-8 in-lb (.7-.9Nm)
Handlebar Clamp Screws: 60-80 in-lb (6.8-9Nm)
Cover Screws: 16-20 in-lb (1.8-2.3Nm) Brake Hose Banjo Screw: 240-264 in-lb (27-30Nm)
Switch Pack Screws: 25-30 in-lb (2.8-3.4Nm)
Brake Hose: 240-264 in-lb (27-30Nm)
1. To remove the brake lever, remove the e clip from the

lever pin.
2. Extract the pin from the housing, then remove the
lever.
3. To remove the parking brake lever, the housing cover
must be removed. Once removed, carefully extract
the spring noting it its position inside the housing.

5.17
Brake Line Replacement 10. Install new brake line on caliper and orientate it as
noted in step 4.
=T
Brake Caliper Banjo Bolt:
BRAKE HOSE FITTING
240-264 in-lb (27-30Nm)
11. Insert the new brake line and install into the master
cylinder. Torque the brake line to specification.
=T
Brake Line-to-Master Cylinder:
BRAKE SWITCH
240-264 in-lb (27-30Nm)
12. Tighten the brake line into the master cylinder in an

orientation so that the line does not have any sharp
COMBINED MASTER CYLINDER SHOWN bends when it is installed on the handlebar.
13. Route the brake light switch in the harness correctly.
Follow these steps if the brake line is to be replaced.
1. Drain the brake system by attaching a clear hose to
the caliper bleed fitting.
2. Attach the other end to a Mity Vac or similar vacuum
tool.
3. Bleed the system of brake fluid.
4. Note the orientation of the brake line. The brake line
will need to be replaced in the same orientation.
Remove the brake line from the caliper assembly. Use
a shop towel to catch any remaining brake fluid in the
hose.
5. On Cyclone master cylinders, remove the banjo bolt,
washers and fitting from reservoir.
6. On combined master cylinder, loosen the brake line
from the master cylinder 1/4 to 1/2 turn.
7. Remove the 4 screws that hold the master cylinder to
the handlebar. This will separate the master cylinder
from the switch pack.
8. Unplug the brake light switch harness from the master

cylinder.
9. Remove the brake line from the master cylinder.

14. On combined master cylinders, place the switch pack Combined MC Brake Light Switch
with the master cylinder onto the handle bar. Two Replacement
smaller screws should be placed on the top and the
longest screw is placed on the lower right. 1. Remove the 4 screws that hold the master cylinder to
the handlebar. This will separate the master cylinder
15. Follow the bleeding procedure. See Brake Fluid
from the switch pack.
Replacement & Bleeding on page 5.16.
Brake Hose Routing

Route brake hose over steering block, under right over
structure tube, and behind coolant surge tank.
5
2. Unplug the brake light switch harness from the master
cylinder.
3. Replace faulty brake light switch into the master
cylinder and route wires correctly.
4. Plug the brake switch back into the harness.
5. Replace the master cylinder to the switch pack and
insert the smaller screws on the top, the longest one
goes into the lower right side.
Phantom Brake Caliper Removal

SILENCER BRACKET
600 RUSH DC-CFI-4 MODELS ONLY
ALL OTHER PHANTOM=WASHERS
CAUTION
Do not pinch brake hose between over structure tubes

and steering block or between hood and hood mounts.
1. Remove the two caliper bolts that hold the caliper and
silencer bracket to the chaincase.
NOTE: DC-CFI-2 models with Phantom calipers do

not feature silencer bracket. Washers are installed in
its place.

5.19
2. Remove the caliper from the chaincase. Tie the Phantom Brake Caliper Piston and Seal
caliper to the overstructure. Do not allow the brake Replacement
caliper to hang from the brake hose.
Phantom Brake Caliper Installation

1. Apply Loctite 242 and replace caliper bolts, and
silencer bracket or washers if equipped. Torque bolts
to specification.
=T PISTON SEAL
Caliper Bolts: 40 ft-lb (54 Nm)

CALIPER BORE PLUG PISTONS
2. Place the brake line on the caliper in the same DO NOT PUSH OR MOVE!
orientation as it was before it was removed.
3. Clean the threads of the banjo bolt and the threads in
the caliper. PISTON SEAL
4. Follow Brake Line Replacement. See Brake Line
Replacement on page 5.18.
5. Install banjo bolt into the caliper and torque it to
specification. CAUTION
6. Bleed the brakes. See Brake Fluid Replacement &
Bleeding on page 5.16. NEVER RE-USE PISTON SEALS. ALWAYS REPLACE
7. Test brake system prior to returning vehicle to service. WITH NEW PARTS.
DO NOT ATTEMPT TO SAND OR POLISH A CALIPER
PISTON.
1. Remove the brake hose from the caliper. Drain the

brake fluid into a jar or suitable container.
2. Rotate and remove the brake pad retaining pin and
then remove the brake pads. Remove the caliper from
the chaincase.
3. Hold the caliper over the brake fluid jar and then push
the pistons back into the caliper. This will push the
brake fluid in the caliper out of the brake hose banjo
fitting hole.
CAUTION
NEVER RE-USE BRAKE FLUID. USED BRAKE FLUID

MAY CONTAIN AIR BUBBLES. ALWAYS USE NEW
BRAKE FLUID FROM A UNOPENED CONTAINER.
4. Clamp the end of a 1/4 thick 2 x 10 piece of steel to

the workbench. Allow the piece of steel to hang off of
the bench by 4 - 5.

5. Position the caliper over the steel plate with the plate 12. Coat the piston thoroughly with new brake fluid.
firmly against one of the retracted pistons. Evenly insert each piston into the bores, working each
in by hand carefully and slowly. Push each piston
CAUTION down until bottomed out.
13. Reinstall the brake caliper on to the chaincase.
DO NOT PUSH ON THE CALIBER BORE PLUG. Torque fasteners to specification.
DOING SO WILL BREAK THE PLUG SEAL AND
REQUIRE CALIPER REPLACEMENT. =T
WARNING Caliper Mounting Screws: 18-20 ft-lb (24-27 Nm)
14. Inspect both brake pads prior to installation. If they are

TO AVOID POSSIBLE INJURY, DO NOT PLACE within the pad wear specification, reinstall into caliper.
FINGERS BETWEEN PISTONS TO ATTEMPT TO
15. Install the brake hose using the same routing and
CATCH THEM WHEN APPLYING COMPRESSED
orientation noted during removal. Torque fitting to
AIR.
specification.
WEAR EYE PROTECTION WHEN APPLYING
COMPRESSED AIR TO CALIPER.
6. Insert a rubber-tipped air nozzle into the brake hose

=T 5
inlet port and apply compressed air to push out the Caliper Banjo Bolt: 240-264 in-lb (27-30Nm)
piston.
7. To remove the second piston, lay a rubber sheet on 16. Fill and bleed the brake system of air. See Brake
the steel plate and position the caliper over the rubber Fluid Replacement & Bleeding on page 5.16.
sheet to seal the open piston bore. Repeat STEP 7. 17. Test brake system prior to returning vehicle to service.
8. Using a plastic or wood pick, remove both piston seals
from the caliper bores. Discard the seals. Phantom Brake Pad Brake Pad
9. Clean the caliper and pistons with denatured alcohol Replacement
and dry with either compressed air or a lint-free rag. Brake pads need to be replaced if the
10. Inspect the caliper bores and pistons for pitting, heavy thickness of the friction material is less
scoring or corrosion. Replace parts if heavily scored than 1/16" (.0625") / 1.5mm.
or pitted. 1. Remove brake pad retaining pin.
11. To assemble the caliper, lubricate two new piston 2. Remove the brake pads.
seals with new brake fluid. Install each seal by
3. Inspect the brake disc for any wear.
inserting one point of the seal into the bore groove,
and then work the seal around the groove with your 4. Replace brake pads in reverse
index finger. Do not twist, or rip the seals. order of removal.
1/16(.0625") / 1.5mm
5. Test brake system prior to returning
vehicle to service.

5.21
Phantom Lite Brake Caliper Bracket/Seal/
Piston Service SPRINGS
CAUTION
NEVER RE-USE PISTON SEALS. ALWAYS REPLACE

WITH NEW PARTS.
DO NOT ATTEMPT TO SAND OR POLISH A CALIPER
PISTON.
5. Push the caliper mounting bracket against caliper.

6. Remove both friction pads.
1. Clean the friction pad area.

2. Remove the brake caliper from the chain case. Slide
the caliper off of the brake disc.
3. Remove the brake hose from the caliper. Drain the 7. Extract bracket by pulling it out of caliper. Note spacer
brake fluid from the master cylinder and caliper into a o-ring on large diameter pin.
suitable jar or container.
CAUTION
NEVER RE-USE BRAKE FLUID. USED BRAKE FLUID

MAY CONTAIN AIR BUBBLES. ALWAYS USE NEW
BRAKE FLUID FROM A UNOPENED CONTAINER.
4. Remove the two anti-rattle springs. If springs are

damaged or rusted, discard and replace with new
springs.
O-RING

8. Remove the two small and two large o-rings from the 15. Coat the piston thoroughly with new brake fluid.
inside of mounting ears on caliper. Discard the o- Evenly insert piston into the bore, working it in by hand
rings. Do not damage the shaft bores when removing carefully and slowly. Push piston down until bottomed
o-rings. out.
9. Thoroughly clean the bracket pins and pin bores with 16. Install two new small and two new large o-rings into
brake cleaner. the caliper for the bracket pins.
10. To remove piston, insert a rubber-tipped air nozzle 17. Apply a liberal amount of silicone-based grease to the
into the brake hose inlet port and apply compressed bracket pins and pin bores. Install the bracket into the
air to push out the piston. caliper.
18. Inspect both brake pads prior to installation. If they are
WARNING within the pad wear specification, reinstall into caliper.
Install two new anti-rattle springs.
TO AVOID POSSIBLE INJURY, DO NOT PLACE 19. Install the brake hose using the same routing and
FINGERS BETWEEN PISTON AND CALIPER TO orientation noted during removal. Torque fitting to
ATTEMPT TO CATCH IT WHEN APPLYING specification.
COMPRESSED AIR.
WEAR EYE PROTECTION WHEN APPLYING
=T
COMPRESSED AIR TO CALIPER.
11. Using a plastic or wood pick, remove both piston seals Caliper Banjo Bolt: 240-264 in-lb (27-30 Nm)
5
from the piston bore. Discard both seals.
20. Reinstall brake caliper assembly on chain case.
Torque fasteners to specification.
=T
Brake Caliper Mounting Fasteners:
20-22 ft-lb (27-30 Nm)
21. Fill and bleed the brake system of air. See Brake
Fluid Replacement & Bleeding on page 5.16.
12. Clean the caliper bore and piston with denatured

alcohol and dry with either compressed air or a lint-
free rag.
13. Inspect the piston and piston bore for pitting, heavy
scoring or corrosion. Replace parts if damaged.
14. To assemble the caliper, lubricate two new piston
seals with new brake fluid. Install each seal by
inserting one point of the seal into the bore groove,
and then work the seal around the groove with your
index finger. Do not twist, or rip the seals.

5.23
Phantom Lite Brake Pad Replacement 12. Test brake system prior to returning vehicle to service.
NOTE: Always replace both friction Brake Pad

pads at the same time.
Brake pads need to be replaced if the

thickness of the friction material is less
than 1/16" (.0625") / 1.5mm.
1. Clean the friction pad area and
master cylinder cover.
2. Remove the two caliper mounting
mount bolts and slide the caliper
assembly off the disc.
1/16(.0625" )/1.5mm
3. Remove master cylinder cover.
4. Prior to removing old pads from
caliper, insert a large C-clamp placed on the head of
the banjo bolt and the backing plate, tighten C-clamp
carefully until piston is pushed back into the bore, do
not over tighten, Piston should move easily. If no C-
clamp is available insert a flat blade of large
screwdriver between pads and pry apart. This action
should press the caliper piston back into its bore, to
make room for the new pads. Monitor the master
cylinder during piston push back and remove any
excess fluid that is forced back into the reservoir to
prevent spillage.
5. Slide bracket tight to caliper and remove worn friction
pads and install the new pads making sure that the
friction material is facing inwards.
6. Insure slider bores are greased well with silicone-
based grease.
7. Install bracket into slider bores.
8. Install new pads making sure that the friction material
is facing inwards.
9. Reposition the caliper over the brake disc, insert and
torque mounting bolts to specification.
=T
Brake Caliper Mounting Fasteners:
20-22 ft-lb (27-30Nm)
10. With the unit reassembled, actuate the brake lever

lightly and slowly several times to seat the new pads
against the disc.
11. Check master cylinder reservoir for proper fluid level
and replace cover. Torque screws to specification.
=T
Master Cylinder Reservoir Screws:
240-264 in-lb (27-30Nm)

Brake Disc Replacement 6. Prior to installation, clean brake disc with brake
cleaner, or denatured alcohol. Dry with compressed
NOTE: Reference Brake Disc Hardware table before air or lint-free towel.
reinstalling brake disc. 7. Install brake disc on to jackshaft. Reinstall correct
brake disc hardware.
YEAR/ 8. Reinstall the brake caliper assembly. Torque caliper
BRAKE DISC FASTENER HARDWARE
CALIPER TYPE bolts to specification.
2010/ Flat Washer
Phantom 1-2 Float Washers =T
Fastener: 40 ft-lb (54 Nm) Brake Caliper Bolts: 40 ft-lb (54 Nm)
Phantom Wave Washer 10. Lock the parking brake. Torque brake disc bolt to
1 Float Washer specification.
Phantom Lite Domed Washer (Dome facing out.)
=T
5
Brake Disc Bolt:
2010: 29 ft-lb (40 Nm)
2011-CURRENT: 40 ft-lb (54 Nm)
1. Engage the parking brake. Loosen the brake disc bolt.

2. Disengage the parking brake.
3. Remove the brake caliper from the chaincase. Tie the
caliper to the overstructure. Do not allow the brake
caliper to hang from the brake hose.
4. Remove the brake disc bolt, beveled washer and shim
washer(s) if model is equipped with the phantom
brake caliper.
5. Remove the brake disc from the jackshaft.
Brake Disc Service Specifications:
Lateral Run-Out Service Limit = .010" (.254mm)
Service Limit Thickness = .030" (.762mm) less

than nominal
Nominal Thickness = .197".005" (5.127mm)

5.25
NOTES

PVT System
CHAPTER 6
PVT System
PVT SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.2
PVT SYSTEM FASTENER TORQUES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.3
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.4
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.4
DRIVE CLUTCH SPRINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.5
SPRING FREE LENGTH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.6
DRIVE CLUTCH WEIGHTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.6
PERC TEAM LWT DRIVEN HELIXES (24 FIN) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.7
TEAM RAMP ANGLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.7
TEAM DRIVEN SPRINGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.8
POLARIS P2 DRIVEN NON-TABBED SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.9
POLARIS P2 TABBED DRIVEN SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.9
POLARIS P2 DRIVEN HELIXES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.10
P2 HELIX ANGLES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.10
DRIVE BELTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.11
BELT INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.11
BELT WEAR / BURN DIAGNOSTICS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.12
DRIVE BELT REMOVAL - TEAM DRIVEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.13
DRIVE BELT INSTALLATION - TEAM DRIVEN . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.13
ADJUSTING BELT DEFLECTION - TEAM DRIVEN CLUTCH . . . . . . . . . . . . . . . . . . . .6.13
DRIVE BELT REMOVAL - SPA P2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.14
DRIVE BELT INSTALLATION - SPA P2 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.14
6
ADJUSTING BELT DEFLECTION - SPA P2. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.14
PVT SYSTEM ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.15
CLUTCH ALIGNMENT/OFFSET. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.15
OFFSET/FLOAT ADJUSTMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.15
ADJUSTING ENGINE MOUNT BOLTS/ENGINE ALIGNMENT . . . . . . . . . . . . . . . . . . .6.16
DRIVE CLUTCH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.17
IDENTIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.17
DRIVE CLUTCH REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.17
DRIVE CLUTCH DISASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.18
ROLLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.19
ROLLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.19
SPIDER BUTTON INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.19
BUSHING/INSERT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.20
MOVEABLE SHEAVE BUSHING/INSERT REMOVAL AND INSTALLATION . . . . . . . .6.20
COVER BUSHING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.20
CLUTCH ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.21
BELT-TO-SHEAVE CLEARANCE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.21
SPIDER INDEXING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.22
DRIVE CLUTCH INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.23
DRIVEN CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.23
DRIVEN CLUTCH REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.23
DRIVEN CLUTCH INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.23
TEAM LWT COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.24
POLARIS SPA-P2 DRIVEN CLUTCH COMPONENTS . . . . . . . . . . . . . . . . . . . . . . . . .6.25
PVT SYSTEM TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6.26
DRIVE BELT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.26
DRIVE CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.26
DRIVEN CLUTCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6.26

6.1
PVT System
PVT SYSTEM Engagement RPM
Overview Engine RPM when the force generated by the clutch

weights overcomes the drive spring pre-load force and the
moveable sheave begins to close or pinch the drive belt.
CAUTION The engagement mode continues until no more belt
slippage occurs in the drive clutch. Once 100% belt
Because of the critical nature and precision balance engagement is achieved, the sled will accelerate along the
incorporated into the PVT system, it is absolutely low ratio line until the drive clutch up shift force overcomes
essential that no attempt at clutch disassembly and/or the opposing shift force generated by the driven clutch.
repair be made without factory authorized special tools
and service procedures. Polaris recommends that only Shift Out Over-Rev
authorized service technicians that have attended a
Polaris-sponsored service training seminar and Engine RPM that spikes above the desired operating RPM
understand the proper procedures perform adjustments speed. The shift out RPM should come down to the
or repairs. desired operating RPM, but never below, after the driven
clutch begins to open.
The Polaris drive system is a centrifugally actuated
variable speed belt drive unit. The drive clutch, driven Shift Out RPM
clutch, and belt make up the torque converter system.
Each clutch comes from the factory with the proper Engine RPM at which the up shift force generated by the
internal components installed for its specific engine model. drive clutch overcomes the shift force within the driven
Therefore, modifications or variations of components at clutch. In this mode, the drive clutch will move the belt
random are never recommended. Proper clutch setup and outwards, and the driven clutch will allow the drive belt to
adjustments of existing components must be the primary be pulled down into the sheaves.
objective in clutch operation diagnosis.
During WOT operation, the shift out RPM can be seen as
the maximum, sustained RPM displayed on the
Drive Spring
tachometer. The shift out RPM should be the same RPM
The drive spring opposes the shift force generated by the as the recommended engine operating RPM. If the shift
clutch weights, and determines the neutral RPM, out RPM is above the recommended engine operating
engagement RPM, and wether the engine RPM remains RPM, install heavier drive clutch weights. If the shift out
flat, rises, or falls during shift out. When changing only the RPM is below the recommended engine operating RPM,
drive spring, installing a spring with a lower pre-load rate install lighter drive clutch weights.
will result in a lower engagement RPM speed, while
installing a spring with a higher pre-load rate will result in The shift out RPM should remain constant during both the
a higher engagement RPM. upshift and back shift modes.
Clutch Weight Driven Spring
The clutch weights generate centrifugal force as the drive A compression spring (Team driven / P2) or torsional
clutch rotates. The force generated changes in relation to spring (Polaris P-85 driven clutch) works in conjunction
the engine RPM and with specified weight of each clutch with the helix, and controls the shift rate of the driven
weight. When changing only the clutch weights, a lighter clutch. The spring must provide enough side pressure to
weight will result in a higher engagement RPM, lower grip the belt and prevent slippage during initial
shifting force, and higher shift out RPM. Installing heavier acceleration. A higher spring rate will provide more side
weights has the opposite effect pressure and quicker back shifting but decreases drive
system efficiency. If too much spring tension exists, the
Neutral Speed driven clutch will exert too much force on the belt and can
cause premature belt failure.
Engine RPM when the force generated by the clutch
weights is less than the pre-load force generated by the
drive spring. In this mode, the drive clutch is disengaged.

PVT System
Back-Shifting Driven Helix / Ramp
Back-shifting occurs when the track encounters an The helix cam is the primary torque feedback component
increased load (demand for more torque). Back-shifting is within the driven clutch, regardless of driven clutch type.
a function of a higher shift force within the driven clutch The beginning angle of the helix must transmit enough
than within the drive clutch. Several factors, including torque feedback to the moveable sheave in order to pinch
riding style, snowmobile application, helix angles, and the drive belt while minimizing belt slip. The flatter or lower
vehicle gearing determine how efficient the drive system the helix angle, the more side force will be exerted on the
back-shifts. The desired engine operating RPM should moveable sheave, while the steeper, or higher the helix
never fall below 200 RPM when the drive system back- angle, the less side force will be exerted on the moveable
shifts. sheave.
Final Gearing PVT System Fastener Torques

The final drive gear ratio plays an important role in how
Fastener Torque Note
much vehicle load is transmitted back to the helix. A tall
gear ratio (lower numerical number) typically results in Drive Clutch Bolt 50 ft-lb
lower initial vehicle acceleration, but a higher top-end (All Carbureted) (68 Nm)
vehicle speed. A lower gear ratio (higher numerical Re-torque after
Drive Clutch Bolt running engine.
number) typically results in a higher initial vehicle 80 ft-lb
(All 2007 - Current
acceleration, but a lower top-end vehicle speed. (108 Nm)
CFI)
Choosing the proper gear ratio is important to overall drive
system performance. When deciding on which gear ratio
Driven Clutch Bolt
17 ft-lb
(23 Nm)
6
to use, the operator must factor in the decision where the
Team Helix 60 - 80 in-lb
snowmobile will be ridden, what type of riding will be
Fasteners (7 - 9Nm)
encountered, and the level of performance the operator
hopes to achieve. 12 ft-lb
P2 Cover
(16 Nm)
Gearing a snowmobile too low for extended high-speed
Team Deflection 110 in-lb
runs may cause damage to the drive belt and drive
Jam Nut (12 Nm)
system, while gearing a snowmobile too high for deep-
snow, mountain use may cause premature belt and clutch P2 Deflection 12 ft-lb
wear. Cam (16 Nm) DO NOT
OVER-TORQUE
P2 SPA
Typically, it is recommended to gear the snowmobile with
Deflection 10 ft-lb
a slightly higher ratio than the actual top speed the
Adjuster Screw (12Nm)
snowmobile will ever achieve.
Lock Nut
1:1 Shift Ratio Spider
280-300 ft-lb Apply Loctite
(380-406 Nm) 243 OR
A 1:1 shift ratio occurs when the drive clutch and the driven Loctite 242
clutch are rotating at the same RPM. 290-330 ft-lb
Spider Jam Nut with Primer N
(394-447 Nm)
The mathematical vehicle speed for a given gear ratio at Drive Clutch 100 In. Lbs.
a 1:1 shift ratio is represented in the chaincase gearing Cover (11 Nm)
charts located in the Final Drive Chapter.
Apply Loctite
150-180 in-lb
Starter Ring gear 271
Low / High Ratio (1-1.2 Nm)
Use cross pattern
Low ratio is the mechanical position when the drive belt is
all the way down into the drive clutch, and all the way out
on the driven clutch. High ratio represents when the drive
belt is all the way out on the drive clutch, and all the way
in on the driven clutch.

6.3
PVT System
GENERAL INFORMATION
Special Tools
Team 12 Cooling Fin Driven Clutch Offset Alignment Tool PS-46998
Team 24 Cooling Fin Driven Clutch / P2 Offset Alignment Tool PS-47477
Drive Clutch Puller (3/4 - 16 x 7/16): Fuji 340 / 488 / 440 / 550 Fan and Liquid Engines 2872084
Drive Clutch Puller: All engines through 1998 (Excluding Domestic Twins / Fuji 700-800 XCR) 2870506
Drive Clutch Puller (3/4 - 16 x 14mm): 2000 - Current Domestic Twins / 1999 - 2003 440 / FS-FST
2872085
1999 - 2003 700 - 800 XCR
Drive Clutch Puller (M14 x 1.5mm): 1997 - 1999 Domestic Twins (Excluding 1999 440 XCR) 2871855
Replacement Handle for ALL Clutch Pullers 5020326
Drive Clutch Holding Wrench 9314177-A
Strap Wrench PU-45419
Replacement Strap 305085
Drive Clutch Spider Nut Socket 2870338
Drive Clutch Spider Removal/Installation Tool 2870341
Clutch Pin Punch 2870507
Tapered Reamer - 29mm Short Drive-All Fuji Snow Engines (Excluding 700-800 XCR) 2870576
Tapered Reamer - 29mm Long Drive-755/866 w/original crankshaft / 700-800 XCR /

PS-48587
All Domestic Carbureted (Excluding 600 IQ Racer)
Tapered Reamer - 31mm- All 600/700/800 CFI / 755/866 w/large taper crankshaft / 600 IQ Racer PS-48584
Roller Pin Installation Roller/Bushing Alignment Tool 2870910-A
Drive Clutch Button Removal Tool 2870985
Clutch Bushing Replacement Tool Kit 2871025
Clutch Holding Fixture 2871358-1
Universal Drive/Driven Clutch Compressor (Screw Down Type) PU-50518
Spring-Loaded Roller Pin Installation Roller/Bushing Alignment Tool 8700221
Drive Clutch Compression Tool (Compresses drive clutch without removing clutch from engine.) 2871173

calling SPX @ 1-800-328-6657.

PVT System
Drive Clutch Springs
WIRE FORCE LBS. LOAD

FREE LENGTH +/-
PART NUMBER COLOR DIAMETER @ 2.50 - 1.19 RATE (lbs./
.125
(inches) (+/- 12 LBS.) inch)
7041080 Blue .207 3.55 120 - 300 137
7041945 Almond .218 3.65 140 - 330 145
7041645 Almond/Gold .207 4.00 150 - 290 107
7041818 Black/White .218 3.52 140 - 320 137
7041816 Almond/Black .200 3.75 165 - 310 111
7041922 Almond/Blue .218 3.75 150 - 310 122
7041988 Almond/Red .207 4.27 165 - 310 110
7042083 Black/Green .218 3.38 120 - 340 168
7043681 Black - 3681 .225 3.327 120 - 310 145
7043342
7043076
Black - 3342
Black - 3076
.218
.225
3.46
2.67
140 - 330
40 - 340
145
229
6
7043120 Black - 3120 .225 2.78 60 - 340 213
7043121 Black - 3121 .255 3.05 100 - 340 183
7042287 Black - 2287 .207 3.40 110 - 290 137
NOTE: Springs listed as color - #### will have the last

four digits of the part number painted on the spring
coil. Tag each spring with the part number and spring
force when not in use.

6.5
PVT System
Spring Free Length Drive Clutch Weights
Measure the drive and driven spring free length with the 10 Series Weights
spring resting on a flat surface. Replace spring if out of
specification.
VERIFY SPRING COILS ARE PARALLEL WEIGHT GRAMS(+/- 1gr.) PART NUMBER
COILS ARE NOT DISTORTED/CRACKED
10M - R 44 1321530
10M - W 46 1321527
In addition to proper free length, the spring coils should be
parallel to one another when placed on a flat surface. 10M - B 47.5 1321529
Distortion of the spring indicates stress fatigue. 10M 49.5 1321528
Replacement is required. 10 51 1321526
10A - L 52.3 1321531
CAUTION 10-54 54 1321685
10A 55 1321589
Never shim a drive clutch spring to increase its 10-56 56 1321684
compression rate. This may result in complete stacking 10-58 58 1321588
of the coils and subsequent clutch cover failure
10-60 60 1321587
10-62 62 1321586
10-64 64 1321585
10-66 66 1321584
10-68 68 1322427
10-70 70 1322414
10-72 72 1322428
10-74 74 1322429
10-76 76 1322585
10-78 78 1322586

PVT System
11 Series Weights PERC Team LWT Driven Helixes (24 Fin)

5135401 64 / 42 - .36
5135402 64 / 38 - .25
5135403 56 / 42 - .36
5135503 54 / 38 - .25
5135504 S36
5135772 66 / 44 - .46
5136327 60 / 42 - .36
5136255 S42
Team Ramp Angles
WEIGHT GRAMS(+/- .8gr.)

11-40
PART NUMBER
1322593
6
11-42 1322592
11-44 1322591
11-46 1322596
11-48 1322590
11-50 1322589
11-52 1322595
11-54 1322866
11-56 1322865 The angles and length of the transition between the first
and final angle is stamped on the back of the helix. The first
11-58 1322864 number (A) designates the starting angle of the ramp. The
11-60 1322863 second number (B) designates the finish angle. The last
11-62 1322862 number (C) is the transition distance (in inches) between
11-64 1322604 the starting and finish angles.
11-66 1322559
11-68 1322558 CAUTION
11-70 1322523
11-72 1322524 Do not install a non-ER helix on a Perc-equipped
snowmobile where the engine changes directions.
11-74 1322525
11-76 1322526
NOTE: When compared to 10 series weights, 11

series weights feature more weight distribution at the
beginning of the shift curve, a more aggressive shift
curve, and a larger heel angle. The belt-to-sheave
clearance will require adjustment when changing to
and from each series of weights.
When cross referencing 10 and 11 series weights,
select a 2 gr. lighter 11 series weight (10-66 = 11-64).

6.7
PVT System
Team Driven Springs
TEAM Driven Springs

PART Free Length
COLOR LOAD @ 2.2 (lbs) LOAD @ 1.1 (lbs) Rate (Lbs. per inch)
NUMBER Inches (cm)
7042181 Black/Yellow 6.0 (15.24) 145 208 56

7043058 Red/Black Subs to 7043149 - P2 Non-Tabbed
7043059 Red/Green 4.767 (12.1) 120 220 90
7042066 Green/Black 5.60 (14.2) 135 198 56
7043061 Red/Silver 4.95 (12.5) 125 175 45
7043062 Red/Yellow 4.40 (11.2) 100 150 45
7043057 Red/Blue 4.767 (12.1) 140 200 54
7043063 Black Subs to 7043150 - P2 Non-Tabbed
7043064 Blue/Black Subs to 7043152 - P2 Non-Tabbed
7043060 Red/White 4.95 (12.5) 100 200 91
7043069 Red/Pink 3.50 (8.9) 140 260 110
7043363 Black/Purple 4.50 (11.4) 160 240 72
7043252 Black - 160 / 280 3.70 (9.4) 160 280 109
7043254 Black - 140 / 300 3.20 (8.1) 140 300 146
7043255 Black - 160 / 300 3.50 (8.9) 160 300 127
7043256 Black - 180 / 300 3.90 (9.9) 180 300 109
NOTE: Team driven springs listed with a color - ### /

### will have the beginning and ending spring rates
painting on the spring coils. Tag each spring with the
part number when not in use.

PVT System
Polaris P2 Driven Non-Tabbed Springs
TEAM
PART Free Length
COLOR LOAD @ 2.2 (lbs) LOAD @ 1.1 (lbs) Rate (Lbs./In.) EQUIVALENT
NUMBER Inches (cm)
COLOR
7043397 4.4 (11.2) 100 150 45 RED/YELLOW
7043398 4.95 (12.6) 125 175 45 RED/SILVER
7043151 4.76 (12.1) 140 200 54 RED/BLUE
7043150 BLACK 4.2 (10.6) 140 220 65 BLACK
7043430 4.4 (11.2) 160 240 72 BLACK/PURPLE
7043152 4.1 (10.4) 120 200 73 BLUE/BLACK
7043149 4.7 (11.9) 140 240 90 RED/BLACK
Polaris P2 Tabbed Driven Springs
PART Free Length*

COLOR LOAD @ 2.4 (lbs) LOAD @ 1.4 (lbs) Rate (Lbs./In.)
NUMBER Inches (cm)
7043515
7043495
4.77 (12.1)
4.74 (12)
130
140
180
200
54.5
60.9
6
BLACK
7043496 4.4 (11.2) 145 220 73
7043512 3.74 (9.5) 120 210 91
NOTE: Tag each spring with the part number and

spring force when not in use.
* = Not including tab.

6.9
PVT System
Polaris P2 Driven Helixes Arc to Straight Angle Helix: 56/42 .45 Example
1st Angle at .100 from Horizontal / 2nd Angle - Vertical
PART NUMBER DESCRIPTION Distance to Transition
5136975 38S
5137154 40S
5137155 42S
5137160 44S
5137142 58/40 - .35
5137150 40/38 - .45
5137157 44/38 - .45
5137176 58/42 - .45
5137153 60/40 - .45
P2 Helix Angles
Straight Angle Helix: 42S Example
Dual Straight Angle Helix: 48/40 .40S Example

1st Angle / 2nd Angle - Vertical Distance to Transition

PVT System
Drive Belts
Center
Projected Overall Outer
Part to
Width Side Circumference Ride Out Notes
Number Center
(IN/CM) Angle (IN/CM)
(IN/CM)
MBL Kevlar Cords

Belt cord line Performance replacement for the
3211122 should be flush 3211080
with, or slightly Cut Finish
11.5 /
1.46 / 37.1 26_ 46.77 / 118.8 above, the outer
29.2 MBL High Performance / Mountain
circumference of
driven clutch Belt
3211115
sheaves. PBO Fiber Cords
Cut Finish
Belt dimensions are given in nominal dimensions. There is Belt Inspection

a +/- variance for all critical dimensions. Clutch set up must
be inspected when a new belt is installed.
The drive belt is an important component of the converter

system. In order to achieve maximum efficiency from the
converter, drive belt tension (deflection), clutch offset, and 6
alignment must be adjusted properly.
The belt cord line should be flush with, or slightly above, 1. Measure the belt width and replace it if it is worn
the outer circumference of the driven clutch sheaves. The severely. Generally a belt should be replaced if the
belt will seat itself in the driven clutch during the break-in clutches can no longer be adjusted to provide the
period. Adjust the belt ride out after the break-in period by proper belt deflection.
re-adjusting belt deflection.
Project the side profiles and measure from corner
The break-in period for a new drive belt is 30 miles. During to corner.
this time, vary the throttle position under 50% and limit full
Place a straight edge on each side of the drive belt
throttle use.
and measure the distance where the straight
edges intersect at the top.
New drive belts that feature a sanded finish should be first
washed with warm, soapy water and allowed to air dry 2. Inspect the belt for loose cords. missing cogs, cracks,
prior to use. abrasions, thin spots or excessive wear spots.
Replace if necessary.
Always take time to warm up the belt and driveline prior to 3. Inspect the belt for hour glassing (extreme circular
operating the snowmobile. Free track and skis from the wear in at least one spot and on both sides of the belt).
ground before engaging throttle. Hour glassing occurs when the drive train does not
move and the drive clutch engages the belt.

6.11
PVT System
Belt Wear / Burn Diagnostics
POSSIBLE CAUSE SOLUTION
Drive at higher RPM if possible. Gear the machine

Driving at or about engagement RPM for extended
down. Make sure belt deflection is at 1 1/4 to achieve
periods of time in any type of snow condition.
optimum starting ratio.
Be patient. Warm up engine at least 5 minutes or until

it readily responds to throttle input. For the quickest
most efficient drive away in extreme cold weather, take
Cold weather startups drive belt off machine and bring it in to a warm
environment. Break skis and track loose from the snow.
Engage throttle aggressively for short durations for
initial cold drive away
When possible, do not go in deep snow when towing

another machine. Use fast, effective throttle to engage
Towing another machine at or about engagement RPM
the clutch. Not all machines are intended for pulling
heavy loads or other machines.
Spinning track while vehicle is stuck (high RPM, low Lower the gear ratio. Remove windage plates from
vehicle speed, high ambient temp. Example: 8000 driven clutch. If possible, move to better snow
RPM, 10mph actual vehicle speed and 60 m.p.h. conditions and reduce RPM. Avoid riding in very high
indicated on speedometer. ambient temperatures
Break loose snow and ice under tunnel. Allow longer

Ice and snow piled up between track and tunnel
than normal warm-up. Allow belt to warm sufficiently
overnight or after stopping for a long period of time
and increase grip ability on clutch sheaves. Use fast,
(enough to re-freeze the snow).
effective throttle when engaging clutch.
Maintain good state of tune including throttle and choke

synchronization. Check for fouled spark plug(s). Check
Poor running engine (Bog, Miss, Backfire, etc.)
for foreign material in carburetors. Make sure no water
or ice is present in the fuel tank, lines, or carburetors.
Use caution when loading machine. Carbide skags may

gouge into trailer and prevent drive train from spinning
freely. Use enough speed to drive completely onto
Loading machine on trailer
trailer. If machine cannot be driven completely onto
trailer, it may need to be pulled or pushed to avoid belt
wear / burning.
Check for correct clutch components, or damage on the

Clutch malfunction
clutch
Slow, easy belt engagement - easing on the throttle Use fast, effective throttle to engage the clutch.

PVT System
Drive Belt Removal - Team Driven
A C
Adjusting Belt Deflection - Team Driven

6
NOTE: Turn the key to the OFF position and allow
the engine to come to a complete stop. Clutch
1. Verify the driven clutch is not in reverse. Remove the
LH compartment door panel.
CAUTION
Damage to the driven clutch or L wrench will occur when

attempting to open the driven clutch when the driven
clutch is in the reverse position.
2. Insert the L wrench, PN 2874857 (A), into the

threaded hole (B) located on the driven clutch, and JAM NUT
turn it clockwise until the clutch sheaves are in the
open position (C). DEFLECTION STUD
3. Remove the drive belt.
Drive Belt Installation - Team Driven 1. Loosen the jam nut.

2. Using an 1/8 Allen head wrench, turn the stud
1. With the L wrench inserted into the threaded hole (B) counter-clockwise to decrease belt deflection and
and the sheaves in the open position, install the drive clockwise to increase belt deflection.
belt. 3. When the proper belt deflection is achieved torque the
lock nut to specification.
NOTE: Install belt so that the numbers can be read
correctly on the left side of the machine or in the
direction in which the belt was originally installed.
=T
2. Remove the wrench. Wiggle the belt to remove slack Deflection Set Screw Lock Nut:
while removing the wrench. 90-110 in-lb. (10-12 Nm)
3. Close the clutch guard.

6.13
PVT System
Drive Belt Removal - SPA P2 Drive Belt Installation - SPA P2
1. With the L wrench inserted into one of the threaded
holes and the sheaves in the open position, install the
drive belt.
NOTE: Install belt so that the numbers can be read

correctly on the left side of the machine or in the
direction in which the belt was originally installed.
2. Remove the wrench. Wiggle the belt to remove slack

while removing the wrench.
Adjusting Belt Deflection - SPA P2

1. Loosen the deflection screw jam nut.
2. Using a 1/8 Allen driver, turn the deflection screw in
or out to adjust the distance between the driven clutch
sheaves.
3. When the proper belt deflection is achieved torque the
lock nut to specification.
THREADED HOLES JAM NUT
NOTE: Turn the key to the OFF position and allow

the engine to come to a complete stop.
1. Verify the driven clutch is not in reverse. Open the LH

compartment door panel.
CAUTION
Damage to the driven clutch or L wrench will occur when

attempting to open the driven clutch when the driven
clutch is in the reverse position.
2. Insert the L wrench, PN 2874857, into one of the

DEFLECTION SCREW
threaded holes located on the driven clutch. Turn it
clockwise until the clutch sheaves are in the open
position. =T
Deflection Screw Lock Nut: 110 in-lb (12 Nm)

PVT System
PVT SYSTEM ADJUSTMENTS
Clutch Alignment/Offset Driven Clutch Offset/Shim Washers
The drive and driven clutches are offset from each other. Offset Washers
This offset is controlled by the number and thickness of 16 Gauge Bushing=7556509 (QTY.1)
washers installed on the jackshaft behind the driven .023 = 7555917 (AR)
clutch. .120 = 7555864 (AR)
Float Washers
1. Remove drive belt. .065" = 7555806 (AR)
.105" = 7555832 (AR)
2. Push the driven clutch towards the bulkhead. Install
the alignment tool into the drive clutch and on top of
the driven clutch hub. AR = As Required
TOOL PART NUMBER APPLICATION

CAUTION
PS-47477 Light Weight (LWT) Team Driven / P2
Always verify the driven clutch floats on the jackshaft.
NOTE: The PS-47477 offset tool is calibrated with the The jackshaft bearing will fail from side-loading if the
correct alignment angle for the respective driven driven clutch is not allowed to float.
clutch.
Inspect for broken motor mounts, engine straps or

0 - .060
6
bulkhead damage if the offset tool reveals major mis-
alignment.
3. The optimum setup is when the front and rear of the

PUSH CLUTCH
tool touch the driven clutch. No gap should be present
in the front, and the rear clearance should not exceed
.060" (1.5mm).
NOTE: If the front of the alignment bar does not touch

the driven sheave, the maximum clearance cannot
exceed .025 (.64mm).
Offset/Float Adjustment
1. Determine direction driven clutch needs to be
adjusted.
2. Remove driven clutch retaining bolt, and remove TOUCHING
driven clutch.
3. With one 16 GA. bushing installed, add or remove
offset washers from behind the driven clutch to set the
proper offset.
4. After adjusting the offset, add or remove shim
washers from behind the driven clutch bolt and
washer to provide a .060" (.1.5mm) driven clutch float
on the jackshaft.
(PN: PS-46998 Shown)

6.15
PVT System
Adjusting Engine Mount Bolts/Engine 4. Once clutch alignment is set, tighten the engine mount
Alignment bolts to specification in the sequence shown in the
illustration.
Minor adjustments to the engine mount bolts and MAG-
front engine mount can be performed if the alignment tool
indicates major clutch mis-alignment.
1. Loosen, but do not remove, the four engine mount

bolts. 4
3
2
1
=T
2010 - 14mm Head Diameter - DK.Green Color
DK. GREEN-M10x1.5x45 (8.8): 30 ft-lb (41 Nm)
2. Loosen, but do not remove, the two Torx screws
securing the MAG-front engine mount to the 2011 - 14mm Head Diameter - Silver/Gray Color
bulkhead. SILVER/GRY-M10x1.5x50 (12.9): 35 ft-lb (48 Nm)
2012/Replacement Kit - 16mm Head Diameter

Silver/Gray Color
SILVER/GRY-M10x1.50 (12.9): 40 ft-lb (54 Nm)
5. Torque the two Torx screws only after all four engine
mount bolts are torqued to specification.
=T
Front-MAG Engine Mount Screws-to-Bulkhead
Screws: 22 ft-lb (30 Nm)
6. Re-check clutch alignment. If clutch alignment is still

incorrect, inspect the engine mounts, motor straps,
radial inserts, and chassis for broken or twisted
components.
3. Verify clutch alignment has changed using the Clutch

Alignment Tool part number: PS-47477. The engine
can be moved slightly with the screws loosend at the
MAG-front location.

PVT System
DRIVE CLUTCH
Identification
A
B B
C D
E
Every clutch will have the clutch part numbers etched on

to the cover (A). The X" (B) marking is an index mark
clutch puller, and repeat this step.
6
where the clutch cover (C), clutch spider (D) and the CAUTION
stationary sheave (E) should line up when the clutch is
assembled. Do not use an impact wrench to remove or install the
clutch bolt or clutch puller. Damage to the clutch and/or
Drive Clutch Removal crankshaft can occur.
NOTE: All clutch tools can be found at the beginning

of this chapter.
1. Remove the belt.
2. Place the clutch holding tool (PN 9314177-A) on the
drive clutch.
3. Remove the drive clutch retaining bolt. Note the
placement and number of washers on retaining bolt.
4. Insert the correct clutch puller into the retaining bolt
hole.
5. Tighten the puller into the clutch. If the clutch does not
come off, strike the clutch puller head with a hammer.
If the clutch does not pop off, continue to tighten the

6.17
PVT System
Drive Clutch Disassembly
ROLLER WEIGHT
WEIGHT PIN
WASHER ROLLER PIN
SPIDER BUTTON SHIM BEARING SLEEVE
MOVEABLE INSERT
SPRING
JAM NUT
COVER
SPIDER
COVER BEARING SPACERS
RETAINER MOVEABLE SHEAVE
CLUTCH SPACER STATIONARY SHEAVE
8. Mount the drive clutch securely in a drive clutch

holding fixture (PN 2871358).
9. Remove the jam nut in a counterclockwise direction
CAUTION (standard thread) using the drive clutch spider nut
socket (PN 2871358).
Wear eye protection when servicing the drive clutch. 10. Install the spider removal tool (PN 2870341), and
Sheaves must be marked to provide a reference point remove the spider in a counterclockwise direction
for clutch balance and spider indexing. If the sheaves (standard thread).
are not marked and the spider washers are changed or 11. Measure the total thickness of the spacer washers
misplaced, the clutch may be out of balance and that are installed on top of the clutch spacer. Record
damage to the clutch may result. the thickness of these spacer washers.
12. Inspect both sheave surfaces for wear or damage.
WARNING 13. Inspect the moveable sheave bushing for wear or
damage.
Clutch spring is under extreme tension, use caution and 14. Remove all three drive clutch weights.
wear eye protection when disassembling the clutch. 15. Inspect each weight. The surface should be smooth,
with no waves or galling. Place pin inside weight to
1. In a straight line, mark/etch the sheaves and the cover check flyweight bushing and pin surface for wear by
with a black marker or a scribe. rocking the weight back and forth.
2. Place the drive clutch in the clutch compression tool 16. Inspect all the rollers, bushings and roller pins by
(PN 8700220). pulling a flat metal rod across the roller.
3. Compress the clutch in the compression tool, then 17. Roller can also be inspected by rolling with a finger to
secure the chain. feel for flat spots, roughness, or loose bushing.
4. Evenly remove the cover fasteners. The cover
bushing may be damaged if the cover is side-loaded NOTE: The flyweight bushing is not replaceable. If
or mis-aligned. flyweight bushing is damaged both the flyweight, pin
and nut will need to be replaced.
5. Carefully remove the tension from the compression
tool.
18. Inspect to see if the roller and bushing are separating.
6. Remove the cover and inspect the cover bushing.
19. Bushing must fit tightly in roller.
Replace if damaged or worn.
20. Replace roller and pin if roller fails to roll smoothly (no
NOTE: Replace the cover bushing if the inside flat spots) or if the bushing is loose or worn.
diameter is over 1.40 (28.95mm)
7. Remove the spring.

PVT System
Roller Removal Spider Button Installation
1. A shim kit is available which contains an assortment
BUTTON of shims.
Drive Clutch Shim Kit

ROLLER PIN
SPIDER PN 2200387
2. Measure the width of the moveable sheave towers

and record. Specification is 1.50"+/- .001" (38.1mm).
WASHER
SHIM
ROLLER
BUTTON
WASHER
1. With the spider in a vise start removing the spider

buttons by drilling a 0.18" hole in the center of a button
on one side of the spider. 3. Measure the width of each corresponding spider leg
2. Place a pin punch through the drilled hole in the button
and drive the opposing button and pin out.
with the buttons installed and record. Specification is
1.496"+/- .001" (37.99mm).
6
3. Remove shims (if any are installed) and note their
location.
4. Flip the spider over and tap out the holed button.
5. Perform steps on remaining spider legs.
NOTE: When required, button shims are installed on

the trailing (right) side of the spider leg as viewed from
the front of spider.
4. Subtract the spider measurement form the tower
measurement. The clearance between the spider
Roller Installation
buttons and the moveable sheave towers is .001" -
NOTE: Use care to start the pin straight. Aluminum .002" (.025 - .05mm).
burrs could pass through into the roller bushing 5. Add shims beneath each trailing side spider button to
causing it to bind and stick. Also use care to make obtain the specified button-to-tower clearance when
sure the roller remains aligned when the pin is driven assembled at each spider leg.
through. The roller busing could be damaged causing
premature wear and roller failure.
= In. / mm.
1. Drive pin into the spider leg .100" -.125" (0.25 -
0.32cm) beyond the first land of the spider leg.
Button-To-Tower Clearance
2. Install one washer on the portion of the pin that is
.001" - .002" (.025 - .05mm)
protruding from the spider leg.
3. Place roller in spider leg and center it on the pin.
4. Place a second washer on the other side of the roller.
5. Place the spider on a vise.
6. Install pin centering tool (PN 2870401).
7. Drive the roller pin through the second land of the
spider.
8. Repeat process for the other two rollers.

6.19
PVT System
Bushing/Insert Replacement 11. Insert installation tool (Item 1) into center of sheave
and with the towers pointing toward the vise (down),
The drive clutch moveable sheave and cover bushings/ slide the sheave onto the puller rod.
insert are replaceable. Bushing/insert removal and 12. Secure rod nut. turn barrel to apply additional tension
installation can be aided using Bushing Removal and against sheave if required.
Installation Kit. 13. Turn the sheave counterclockwise until bushing is
fully seated.
The kit uses the Piston Pin Puller tool. Each of the
14. Remove the rod nut and installation tool and repeat
adapters and/or tools are marked with an item number.
steps 11 to 13 and install the new insert.
The item number is referenced within the text for
identification.
Cover Bushing
Clutch Bushing Removal / Installation Kit NOTE: A torch may be required to release the
bushing retaining compound.
PN 2871025
Individual Parts:
1. On covers utilizing a retaining ring, remove the ring
P-85 Bushing / Insert Tool = 5020627 (Item 1)
using a pick or scribe.
Cover Bushing Tool = 5020629 (Item 3)
Main Puller Adapter = 5020632 (Item 8) 2. Install the main adapter (Item 8) onto the puller tool.
3. From outside of the cover, insert the removal tool
Piston Pin Puller Tool (Item 3) into the cover bushing.
4. With the inside of the cover facing the vise, slide the
PN 2870386 cover onto the puller.
5. Secure the rod nut. Turn the puller barrel to apply
Moveable Sheave Bushing/Insert Removal tension if required.
and Installation 6. Turn the clutch cover counterclockwise until the
bushing is removed and the cover comes free.
NOTE: A torch may be required to release the
7. Remove the tools and discard the bushing.
bushing retaining compound.
8. To install a new cover bushing, apply Loctite 648 to
1. Disassemble the clutch and remove the moveable the leading edge of the new bushing. Insert the new
sheave from the stationary shaft. bushing and bushing installation tool (Item 3) from the
inside of the cover.
2. Install handle end of the piston pin puller securely into
a bench vise.
NOTE: Verify no retaining compound is deposited on
3. Install the main adapter (Item 8) onto the puller. the I.D. of the bushing.
4. Working from inside of moveable sheave, insert the
moveable sheave removal tool (Item 1) into the center 9. With the main adapter (Item 8) installed on the puller,
of the sheave. Slide sheave onto puller tool with insert the cover onto the puller rod with the outside of
towers facing upwards. the cover facing the vise.
5. Secure puller nut. turn puller barrel to increase tension 10. Secure the rod nut and tighten the puller barrel to
on the sheave if required. apply more tension if required.
6. Turn sheave counterclockwise on puller rod until it 11. Turn the clutch cover counterclockwise on the puller
comes free. rod until the bushing is fully seated. Remove the tools
7. Remove the sheave from the puller tool rod. from the rod and remove cover.
8. Remove and discard the old bushing and insert. 12. Squeeze the ends of the retaining ring and reinstall
9. To install a new bushing, place the main adapter (Item into the back of the cover.
8) onto the puller rod.
10. Apply a thin film of Loctite 648 to the leading edge
of the new bushing. Push a new bushing into center
of sheave by hand.
NOTE: Verify no retaining compound is deposited on

the I.D. of the bushing.

PVT System
Clutch Assembly 9. Apply Loctite 243 to shaft threads. Do not get
Loctite on moveable bushing.Install the jam nut onto
1. Assemble the rollers, bushings and roller pins if they the shaft and torque it to specification.
were removed.
2. Install the head of the weight pin so that it is on the
leading side of rotation. This will orientate the nut on
=T
the trailing side of rotation.
Spider Jam Nut Torque:
3. Torque weight pin to specification. 290-330 ft-lb (394-447 Nm)
Apply Loctite 243 to Threads
=T
10. Place the drive spring on the shaft.
Weight Pin Torque: 11. Place the cover onto the clutch and torque the cover
20-30 in-lb (2.2-3.4 Nm) fasteners to specification.
4. Place the moveable sheave onto the stationary

sheave.
=T
5. Place the same number of spacers on top of the Cover Fastener Torque:
stepped spacer onto the shaft of the stationary 100 in-lb (11 Nm) Use cross pattern.
sheave.
NOTE: Do not allow side loading or mis-alignment of

SPIDER the cover or the bushing may become damaged.
6
CLUTCH SPACER Belt-to-Sheave Clearance Adjustment
Belt-to-sheave clearance is an important factor when
evaluating drive clutch performance as it controls the
starting drive ratio and the position of the drive clutch
weights in relation to engine RPM.
SPACER(S)
If the clearance is too small, the drive belt will drag on the
JAM NUT face of the sheaves when the engine is at idle speed.
If the clearance is too large, the belt will slip during initial
6. Thread the spider onto the stationary sheave shaft. engagement causing belt burning and low-speed engine
7. Index the spider. See Spider Indexing on page 6.22. bogging.
8. Apply Loctite 243 to shaft threads. Do not get
Loctite on moveable bushing. Using the spider tool
(PN 2870341) torque to specification. = In. / mm.
=T Belt-to-Sheave Clearance:
Nominal = .020in. (0.508mm)
Spider Torque: Range = .005 - .035in. (0.127 - 0.89mm)
280-300 ft-lb (380-406 Nm)
Belt-to-sheave clearance can be adjusted by installing a
different drive belt, or by adding or removing shims
washers) located under the spider assembly.
To measure belt-to-sheave clearance, follow these steps:
1. Verify the drive clutch sheave faces are clean and the
drive belt is in good condition, and not damaged or
excessively worn.
2. Push the drive belt tight against one side of the drive

6.21
PVT System
clutch sheaves. Measure the opposite side gap using
a feeler gauge.
3. A slight drag should be felt when inserting the feeler
gauge between the belt and sheave face.
4. Compare measured gap to the specification. SPIDER
(A)
The distance between the moveable and stationary clutch
sheaves and thus the belt-to-sheave clearance is
determined by the number and thickness of the washer(s)
installed between the spider and clutch spacer. (B)
To increase the clearance, add or install thicker washer(s).

JAM NUT
To decrease the clearance, remove or install thinner
washer(s). Either way, belt-to-sheave clearance
adjustment most often requires the spider to be re-
indexed. 4. Install spider washer(s) and spider aligning the X
with the moveable sheaves X. Notice as the spider
Spider Indexing seat location is changed, the sheave marks made
before disassembly no longer align (C). There are two
NOTE: Spider indexing effects belt to sheave ways to bring the sheave marks into alignment.
clearance and clutch balance. Please read all
procedures before proceeding.
1. Remove and disassemble clutch

2. Add or remove spider washers as required to achieve
desired belt-to-sheave clearance. Make sure that the
stepped washer (A) is on the bottom of the spacer
stack (B). For example: If belt to sheave clearance is
.020 too large, removing one .020 shim will position
the movable sheave closer to the fixed sheave
reducing belt to sheave clearance by .020 .
NOTE: Install the clutch spacer (stepped washer)

with the lip facing the spider.
3. Place the correct number of spacer washers (B)

between the spider and clutch spacer (A) (stepped
washer). The following washers are available for fine
tuning:
5210752 - .020 (.51mm)
5242981 - .025 (.63mm)
5210753 - .032 (.81mm)
5210754 - .050 (1.27mm)
Vary the amount and thickness of spacer washers (washer

thickness may vary slightly). Re-index marked spider leg
to another tower. This can be done because spider has
little effect on overall clutch balance.

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

with in 1" (25.4mm) after final assembly and torquing.
When assembling a new clutch with all of the same
components, it is not uncommon for the marks not to
line up.
Drive Clutch Installation

NOTE: Always clean the clutch taper before re-
installing clutch on engine. A
1. Place the specified clutch taper reamer in a vise and

lubricate the cutting edges with cutting oil. Clean the
clutch taper by manually rotating the clutch clockwise
on the reamer one or two revolutions. Only use the 2. Apply and lock the parking brake.
weight of the clutch and do not push down on the 3. Remove the driven clutch bolt and washers (A).
clutch while turning.
2. Check crankshaft taper for galling or scoring. If
NOTE: Count the number and location of the spacer
6
washers located on the fastener and behind the
necessary clean the taper evenly with 200 grit emery
clutch.
cloth.
3. The clutch taper and the crankshaft taper should be
4. Slide the driven clutch off the jackshaft.
clean and dry. Do not use harsh cleaners which may
cause clutch taper to corrode, or damage the crank 5. Inspect the splines and replace jackshaft if damage is
seal. found.
4. Clean clutch taper with lacquer thinner or isopropyl
alcohol.
Driven Clutch Installation
5. Slide clutch onto crankshaft taper.
6. Install the retaining bolt with all spacers and washers
or o-rings that were on the bolt when it was removed.
7. Hold the clutch with the holding wrench PN 931417-A.
8. Torque bolt to specification.
9. Run engine then re-torque the retaining bolt to
specification.
1. Install the driven clutch bolt with the same amount of

washers at removal.
2. Torque the bolt to specification.
3. Check for correct belt deflection, and the clutch floats
on the shaft.

6.23
PVT System
Team LWT Components
SCREWS
ROLLER ASSEMBLY
HELIX
SNAP RING
SPRING CUP
SPRING DEFLECTION SPACER
STATIONARY SHEEVE
MOVEABLE SHEEVE
BELT DEFLECTION SCREW
double splines on the shaft. Slowly compress the

=T spring and roller assembly down on to the shaft. Install
the snap ring making sure it is fully seated in the
Helix Fasteners: 60-80 in-lb (7-9 Nm) groove.
Driven Clutch Retaining Fastener: 17 ft-lb (23 Nm) 9. Install the helix by aligning the rollers with the ramps.
Push the helix down into the sheave while keeping the
Disassembly and Assembly Process screws holes aligned.
10. Install and torque helix fasteners to specification.
1. Remove the screws from the helix, then carefully pry
the helix out of the moveable sheave, or gently tap =T
shaft on a block of wood.
2. Install the clutch in the clutch compressor fixture, PN Helix Fasteners: 60-80 in-lb. (7-9 Nm)
8700220. Install the extensions, PN PS-45909.
CAUTION
Driven spring under pressure. Wear eye protection

when removing snap ring and helix.
3. Wearing eye protection, carefully compress the roller

assembly to gain access to the snap ring. Remove the
snap ring.
4. Slowly release the fixture arm to remove the roller
assembly and spring. Disassemble the clutch
sheaves.
5. Inspect the sheaves for abnormal wear. Clean sheave
faces with a Scotch Brite pad and a solution of warm,
soapy water.
6. Inspect spring, spring cup, spacer and rollers for wear
and replace as required.
7. To assemble the clutch, slide the components back on
to the stationary sheave shaft.
8. Align the notch in the roller assembly with row of

PVT System
Polaris SPA-P2 Driven Clutch Components
SPACER
MOVEABLE SHEAVE STATIONARY SHEAVE
DRIVEN COVER WASHER
HELIX SPRING w/TAB
SPRING CUP w/TAB HOLES

BUSHING ROLLER BUSHING SPACER
(NO SERVICE) RETAINING RING (NO SERVICE)
WASHER
ADJUSTER SCREW / LOCK NUT
3. Remove the snap ring. Verify the washer is not lodged

=T inside the snap ring groove.
Driven Cover Screws: 12 ft-lb (16Nm) CAUTION

Deflection Adjuster Screw Lock Nut: 10 ft-lb (12Nm)
Driven Clutch Retaining Fastener: 18 ft-lb (25 Nm)
6
Driven spring under pressure. Wear eye protection
Roller Fasteners: 110 in-lb (12.5 Nm) when removing snap ring and helix.
Disassembly and Assembly Process 4. Unscrew the compressor to remove the helix, spring
cups and spring. Note the orientation of the spring
1. Remove the driven cover screws and cover. Note the spacer, spring cup, and tabbed spring. Disassemble
X in the cover and moveable sheave are in the clutch sheaves.
alignment. 5. Inspect the helix, cup/spacer, spring, bushings,
2. Install the clutch into a screw-down clutch rollers, and clutch sheaves for damage.
compression fixture. Screw-down clutch compressors 6. The cover and sheave bushings are not serviceable.
are commercially available through after-market If bushings are severely worn or binding, clutch
companies such as Team Industries Inc. assembly replacement is required.
7. Clean the sheaves with a Scotch Brite pad and a
solution of warm, soapy water.
8. Inspect the rollers for abnormal wear and replace as
required. Install new rollers with the ejector pin marks
on the rollers facing center of sheave (visible).
9. Install the sheave spacer, and then the moveable
sheave.
10. Next, install the metal spring cup, spring, and then
spring spacer. Make sure the spring tab is in one of
the spring cup holes, and engaged in the moveable
sheave hole.
11. Slide the helix down the stationary shaft.
NOTE: The 8700220 clutch compressor and PS-45909

extensions will not work on a P2 driven clutch.

6.25
PVT System
12. Align the helix alignment hole with the X on the PREMATURE WEAR: Ensure correct belt is
moveable sheave. installed. Inspect belt-to-sheave clearance,
deflection, and clutch alignment.
Adjust gearing for rider type. Verify correct clutch
weight/spring package is installed.
Change riding habits/style.
MOVEABLE MARK
HELIX MARK
OPERATING RPM DROP: Drive belts used on
snowmobiles operated at high speeds/loads
(mountain use) for extended periods of time
should be inspected for glazing at 1,000 mile
intervals.
CORD POP-OUT: Inspect drive/driven clutch

alignment, motor mounts, and deflection. Set
driven clutch float.
13. Align the wide gap in the helix splines with the skip Remove belt during off-season storage period.
tooth in the stationary sheave shaft.
14. Visually verify the rollers are positioned underneath Drive Clutch
each corresponding helix ramp.
PREMATURE WEAR:
15. Compress the helix down into the sheave. Install the Verify correct clutch weight/spring package is
washer and snap ring. Verify the snap ring is fully installed.
seated in the groove with the sharp edge upward. Inspect spider rollers/bushings for damage and
16. Carefully release the clutch compressor. uneven wear.
17. Align the two X marks and install the cover. Torque Inspect sheave faces for premature wear. De-
fasteners to specification. glaze faces with 1500-2000 grit sand paper.
Verify jam nut/spider are torqued to specification.
=T OPERATING RPM DROP:
Replace drive clutch spring and retest.
P2 Cover Fastener Torque: Inspect spider rollers/bushings.
12 ft-lb (16 Nm) Inspect/adjust belt-to-sheave clearance.
Inspect moveable/cover bushings.
PVT SYSTEM TROUBLESHOOTING
Driven Clutch
Drive Belt
PREMATURE WEAR:
Verify specified drive belt is installed on vehicle. Verify correct clutch helix/spring is installed.
Inspect rollers/bushings for damage and uneven
Drive belts have different width, angle and length wear.
measurements. Reference: Drive Belts section Inspect sheave faces for premature wear. De-
for specifications. glaze faces with 1500-2000 grit sand paper.
Verify driven clutch floats on jackshaft.
Installing a non-specified drive belt often requires
drive clutch spacer adjustments to achieve correct OPERATING RPM DROP:
belt-to-sheave clearance. Replace spring and retest.
Inspect spider rollers/bushings.
Install drive belt so part number can be read from
left-side of vehicle. Always install belt using the Inspect moveable/cover bushings.
same orientation as it was before removal.

Shocks
CHAPTER 7
Shocks
SPECIAL TOOLS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.2
SHOCK REBUILDING TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.2
VALVE SHIMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.3
FOX SHOCK VALVE PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.3
WALKER EVANS SHOCK 3/8" VALVE PART NUMBERS . . . . . . . . . . . . . . . . . . . . . .7.4
VALVE SHIM ARRANGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.5
PISTON ORIENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.5
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.6
2010 RUSH SHOCK SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.6
2011 PRO-RIDE MODEL SHOCK SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . .7.9
2012 PRO-RIDE MODEL SHOCK SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . .7.12
SHOCK MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7.15
WALKER EVANS COIL-OVER PIGGYBACK SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . .7.15
WALKER EVANS REMOTE RESERVOIR / PIGGYBACK SHOCK DISASSEMBLY . . .7.15
WALKER EVANS REMOTE RESERVOIR / PIGGYBACK SHOCK ASSEMBLY . . . . . .7.17
FOX IFP MONOTUBE SHOCK DISASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.19
FOX IFP MONOTUBE SHOCK ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.20
FOX IFP MONOTUBE SHOCK ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.21
WALKER EVANS IFP MONOTUBE SHOCK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7.23
WALKER EVANS IFP MONOTUBE SHOCK ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . .7.24

7.1
Shocks
SPECIAL TOOLS
Shock Rebuilding Tools
Special Tools
2200421 Gas Shock Recharging Kit
PS-45259 Gas Fill Tool
PS-45259-1 Gas Fill Tool Repalcement Needles (20 Pack)
2871351 IFP Depth Tool (Fox/Walker Evans)
PS-45629 Shock Body Holding Tool (1 3/4)
2871071 Shock Body Holding Tool (1 5/8)
PS-45281 Shock Body Holding Tool (2 1/8)
2871352 Shock Rod Holding Tool 1/2" Diameter Rod
2872429 Shock Rod Holding Tool 5/8" Diameter Rod
2201639 Shock Shaft Seal Protector 1/2" Diameter
2201640 Shock Shaft Seal Protector 5/8" Diameter
2870623 Shock Absorber Spring Compression Tool
2870803 Shock Spring Pre-Load Adjustment Tool
PS-45908 Walker Evans T-Handle Tool
Ryde FX Shock Special Tools

PS-45260 Ryde FX Lower Retainer Wrench
PS-45261 Ryde FX IFP Positioning / Extraction Tool
PS-45262 Ryde FX Cylinder Head Wrench
PS-45263 Ryde FX Wear Band Tool
PS-45280 Ryde FX Shock Collar Tool
FOX Shock Special Tools

2871232 Fox Shock Spanner
PS-44925 Fox Inner Tube Puller (Position Sensitve Shocks)

calling SPX @ 1-800-328-6657.

Shocks
VALVE SHIMS
Fox Shock Valve Part Numbers
PART NUMBER SIZE THICKNESS

1500055 0.700
1500054 0.800
1500053 0.900
1500048 1.000 0.006
1500049 1.100
1500050 1.250
1500052 1.300
1500029 0.700
1500028 0.800
1500033 0.900
1500032 1.000 0.008
1500031 1.100
1500051 1.250
1500030 1.300
1500044 0.700
1500047 0.800
1500046 0.900
1500045
1500027
1.000
1.100
0.010
7
1500026 1.250
1500062 1.300
1500056 0.700
1500057 0.800
1500058 0.900
1500059 1.000 0.012
1500060 1.100
1500078 1.250
1500079 1.300
1500081 0.700
1500082 0.800
1500083 0.900
1500084 1.000 0.015
1500085 1.100
1500086 1.250
1500087 1.300

7.3
Shocks
Walker Evans Shock 3/8" Valve Part
Numbers
PART NUMBER SIZE THICKNESS

1800051 .700
1800075 .800
1800076 .900
1800077 1.000 .006
1800078 1.100
1800079 1.200
1800080 1.300
1800081 .700
1800082 .800
1800083 .900
1800084 1.000
.008
1800085 1.100
1800086 1.200
1800087 1.250
1800088 1.300
1800052 .700
1800053 .800
1800054 .900
1800055 1.000
.010
1800056 1.100
1800057 1.200
1800379 1.250
1800058 1.300
1800059 .700
1800060 .800
1800061 .900
1800062 1.000
.012
1800063 1.100
1800064 1.200
1800089 1.250
1800072 1.300
1800066 .700
1800067 .800
1800068 .900
1800069 1.000
.015
1800070 1.100
1800380 1.200
1800071 1.250
1800072 1.300
1800090 1.000
1800091 1.100
.025
1800092 1.200
1800093 1.300
1800050 .625 .065
1800204 .875 .090

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

PISTON
SHOCK ROD
REBOUND VALVE STACK COMPRESSION VALVE STACK
Piston Orientation
The face of the piston with the greater number of relief
ports will always face the rebound valve stack
= Relief Port 7
Faces Rebound Stack Faces Compression Stack
NOTE: On some Walker Evans shocks, the piston is

convex and color-coded.
Blue = COMPRESSION SIDE
Red = REBOUND SIDE.
RED
WEARBAND
BLUE

7.5
Shocks
SPECIFICATIONS Valve shim stacks listed as they would appear on the
shaft when shock rod is locked in a table vise (eyelet
2010 Rush Shock Specifications down, threaded end up).
NOTE: All valve code measurements are in inches.
2010 IFS Shock

EXTENDED COLLAPSED SHOCK
STROKE IFP DEPTH
SHOCK PN MODEL LENGTH LENGTH ROD OIL VOLUME PSI
IN IN
IN IN IN
7043436 Walker Evans 18.60 12.16 6.44 .625 2.00 Full 200
2010 IFS Shock

SHOCK 7043436
.625 x .065
.700 x .010
REBOUND
.800 x .010
.900 x .010
.900 x .010
1.00 x .010
1.10 x .008
1.20 x .008
Piston Orifice .052
Shaft Bleed .082
1.30 x .006
.800 x .012
1.20 x .006
COMPRESSION
.900 x .015
1.100 x .006
1.000 x .006
.900 x .006
.800 x .006
.700 x .006
.625 x .065
.875 x .090
ADJUSTER
1.00 X .025
1.00 X .025
.625 X .065

Shocks
2010 Front Track Shock (FTS)
STROKE IFP DEPTH
IN IN
IN IN IN
2010 Front Track Shock

SHOCK 7043412
.625 x .065
.700 x .008
REBOUND
.800 x .008
.900 x .008
1.00 x .008
1.10 x .008
1.25 x .010
1.25 x .010
Piston Orifice .063
1.30 x .010
1.10 x .010
.900 x .010
COMPRESSION
1.30 x .010
1.25 x .010
1.10 x .008
1.00 x .008
.900 x .008 7
.800 x .008
.700 x .008
.625 x .065
Compression
.800 x .006
ADJUSTER
Rebound
1.0 x .025
1.0 x .025
.900 x .015
.625 x .063

7.7
Shocks
2010 Rear Track Shock (RTS)
STROKE IFP DEPTH
IN IN
IN IN IN
2010 Rear Track Shock

SHOCK 7043417
.625 x .065
.700 x .015
.800 x .015
REBOUND
.900 x .015
1.00 x .015
1.10 x .015
1.20 x .015
1.25 x .015
1.25 x .015
1.25 x .015
Shaft Bleed .086
1.300 x .008
1.10 x .008
.900 x .010
COMPRESSION
1.30 x .008
1.20 x .008
1.10 x .008
1.00 x .008
.900 x .008
.800 x .008
.700 x .008
.875 x .090
ADJUSTER
1.00 x .025
1.00 x .025
.625 x .065

Shocks
2011 PRO-RIDE Model Shock Specifications Valve shim stacks listed as they would appear on the
NOTE: All valve code measurements are in inches. down, threaded end up).
2011 IFS Shocks

STROKE IFP DEPTH OIL
SHOCK PN MODEL LENGTH LENGTH ROD PSI
IN IN VOLUME
IN IN IN
7043631 Fox 18.02 12.13 5.89 .498 1.75

7043650
18.0 5.84
7043636 12.16 .625 2.0 Full 200
Walker Evans
7043568 18.6 6.44
7043429 17.5 11.5 6.0 .50 6.875
2011 IFS Shocks

SHOCK 7043631 7043650 7043636 7043568 7043429
.620x.093 .625x.065 .875x.090
.625x.065 .625x.065
.700x.010 .700x.012 .700x.008
.700x.010 .700x.010
REBOUND
.800x.010 .800x.012 .800x.008

.800x.010 .800x.010
.900x.012 .900x.012 .900x.008
.900x.010 .900x.010
1.00x.012 1.00x.012 1.00x.008
1.00x.010 1.00x.010
1.10x.012
.800x.012
1.10x.008
1.20x.008
1.10x.010
1.25x.010
1.10x.012
1.20x.012
1.10x.008
1.20x.008 7
1.250x.006 1.25x.015 1.25x.008
Piston Orifice .093 .052 .042 .040 .052
Shaft Bleed N/A .086 .082 .082 N/A
1.30x.010
1.30x.006 1.30x.008
1.30x.008 1.30x.010 1.20x.008
.800x.012 .900x.010
.800x.010 1.00x.008 1.00x.008
1.20x.006 1.20x.008
COMPRESSION
1.250x.008 .900x.010 .800x.012

.900x.012 .900x.008
1.10x.008 1.20x.008 1.25x.010
1.10x.008 1.25x.010
1.00x.008 1.10x.008 1.20x.010
1.00x.008 1.10x.008
.900x.006 1.00x.008 1.10x.008
.900x.010 1.00x.008
.800x.006 .900x.008 1.00x.008
.800x.010 .900x.008
.700x.006 .800x.008 .900x.008
.700x.010 .800x.008
.620x.020 .700x.015 .800x.008
.625x.065 .700x.010
1.125x.093 .875x.090 .700x.015
.875x.090 .875x.090
.875x.090
REBOUND
ADJUSTER
.800x.012 REBOUND
1.00x.025
COMPRESSION 1.00x.025
N/A 1.00x.025 N/A
1.00x.025 1.00x.025
.625x.065
1.00x.025 .625x.065
.625x.065

7.9
Shocks
2011 Front Track Shocks (FTS)
IN IN VOLUME
IN IN IN
7043632 Fox 11.67 8.33 3.34 .498 .69 250

7043642 11.67 8.33 3.34 2.25
.625
7043634 12.34 8.84 3.5 2.0 Full
Walker Evans 200
7043628 .75
11.75 8.21 3.54 .50
7043602 4.30
2011 Front Track Shocks

SHOCK 7043632 7043642 7043634 7043628 7043602
.625x.065
.625x.065 .625x.065 .625x.065
.620x.093 .700x.008
.700x.008 .700x.010 .700x.008
.700x.008 .800x.008
REBOUND
.800x.008 .800x.010 .800x.008

.800x.008 .900x.008
.900x.008 .900x.010 .900x.008
.900x.008 1.00x.008
1.00x.008 1.00x.010 1.00x.008
1.00x.008 1.10x.008
1.10x.008 1.10x.010 1.10x.008
1.10x.008 1.25x.012
1.25x.010 1.25x.012 1.25x.010
1.250x.008 .900x.006
1.25x.010 1.25x.012 1.25x.010
1.25x.008
Piston Orifice .078 .063 .086 .063 .063
1.30x.008 1.30x.010 1.30x.010
1.30x.008
1.30x.008 1.20x.008 1.10x.010 1.10x.010
.900x.010
.900x.008 .900x.010 .900x.008 .900x.010
COMPRESSION
1.30x.012
1.250x.012 1.30x.010 1.30x.012 1.30x.010
1.25x.010
1.10x.012 1.25x.010 1.25x.012 1.25x.010
1.10x.008
1.00x.012 1.10x.008 1.10x.010 1.10x.008
1.00x.008
.900x.012 1.00x.008 1.00x.010 1.00x.008
.900x.008
.800x.012 .900x.008 .900x.010 .900x.008
.800x.008
.700x.012 .800x.008 .800x.010 .800x.008
.700x.008
1.125x.093 .700x.008 .700x.008 .700x.008
.625x.065
.625x.065 .875x.090 .625x.065
REBOUND
.800x.012
ADJUSTER
1.00x.025
COMPRESSION
1.00x.025
N/A 1.00x.025 N/A N/A
.900x.015
1.00x.025
.625x.065
.900x.015
.625x.065

Shocks
2011 Rear Track Shocks (RTS)
STROKE IFP DEPTH
IN IN
IN IN IN
7043633 Fox 17.29 12.06 5.23 .498 2.26

7043651 17.25 12.0 5.25 .625 2.0
7043635 16.71 10.96 5.75 .50 2.25 Full 200
Walker Evans
7043629 .625 2.0
16.8 11.35 5.45
7043603 .50 6.25
2011 Rear Track Shocks

SHOCK 7043633 7043651 7043635 7043629 7043603
.625x.065
.620x.093 .625x.065 .625x.065
.700x.015 .875x.090
.700x.015 .700x.010 .700x.015
.800x.015 .700x.008
.800x.015 .800x.010 .800x.015
REBOUND
.900x.015 .800x.015
.900x.015 .900x.010 .900x.015
1.00x.015 .900x.012
1.00x.015 1.00x.012 1.00x.015
1.10x.015 1.00x.010
1.10x.015 1.10x.012 1.10x.015
1.20x.015 1.10x.010
1.250x.015 1.25x.015 1.20x.012
1.25x.015 1.20x.010
1.250x.015 1.25x.015 1.25x.015
1.25x.015 1.25x.008
1.250x.015 1.25x.015 1.25x.015
1.25x.015
Piston Orifice
Shaft Bleed
.093
N/A
N/A
.086
.086
N/A
N/A
.082
.069
N/A
7
1.30x.006 1.30x.010 1.30x.008
1.30x.006 1.30x.008
1.10x.006 1.20x.008 1.10x.010
.700x.012 1.25x.006
.800x.012 1.00x.010 .900x.008
COMPRESSION
1.250x.008 .800x.012
1.20x.006 1.25x.012 1.30x.010
1.10x.008 1.25x.010
1.10x.006 1.20x.008 1.20x.010
1.00x.006 1.10x.010
1.00x.006 1.10x.008 1.10x.010
.900x.006 1.00x.010
.900x.008 1.00x.008 1.00x.010
.800x.006 .900x.010
.800x.008 .900x.008 .900x.010
.700x.006 .800x.010
.700x.008 .800x.008 .800x.010
.620x.020 .700x.010
.625x.065 .700x.008 .700x.008
1.125x.093 .625x.065
.875x.090 .875x.065 .875x.090
REBOUND
.800x.012
ADJUSTER
1.10x.025 REBOUND
COMPRESSION
1.10x.025 1.00x.025
N/A 1.00x.025 N/A
1.00x.025 1.00x.025
1.00x.025
.875x.090 .625x.065
.900x.015
.625x.065

7.11
Shocks
2012 PRO-RIDE Model Shock Specifications Valve shim stacks listed as they would appear on the
NOTE: All valve code measurements are in inches. down, threaded end up).
2012 IFS Shocks

(INCHES) (INCHES) VOLUME
(INCHES) (INCHES) (INCHES)
7043725 Fox 17.19 11.15 6.04 .498 1.07
7043731 17.3 11.45 5.85 .625
7043749
17.7 11.63 6.07 .625 2.0 Full 200
7043757 Walker Evans
7043568 18.6 12.16 6.44 .625
7043429 17.5 11.5 6.0 .50 6.875
2012 IFS Shocks

SHOCK 7043725 7043731 7043749 7043757 7043568 7043429
.620x.093 .625x.065 .625x.065 .625x.065 .875x.090
.625x.065
.700x.012 .700x.008 .700x.008 .700x.012 .700x.008
.700x.010
REBOUND
.800x.012 .800x.008 .800x.008 .800x.012 .800x.008

.800x.010
.900x.012 .900x.008 .900x.008 .900x.012 .900x.008
.900x.010
1.0x.012 1.0x.008 1.0x.008 1.00x.012 1.00x.008
1.0x.010
1.10x.012 1.10x.008 1.10x.008 1.10x.012 1.10x.008
1.10x.010
.800x.012 .800x.010 .800x.010 1.20x.012 1.20x.008
1.20x.010
1.25x.006 1.20x.006 1.20x.006 1.25x.015 1.25x.008
Piston Orifice .093 .052 .052 .042 .040 .052
Shaft Bleed N/A .086 N/A .082 .082 N/A
1.30x.010
1.30x.006 1.30x.006 1.30x.008
1.30x.008 1.30x.010 1.20x.008
.800x.012 .800x.012 .900x.010
.800x.010 1.00x.008 1.00x.008
1.20x.006 1.20x.006 1.20x.010
COMPRESSION
1.25x.012 .900x.010 .800x.012

.900x.012 .900x.012 .900x.008
1.10x.012 1.20x.008 1.25x.010
1.10x.008 1.10x.008 1.25x.010
1.0x.008 1.10x.008 1.20x.010
1.0x.008 1.0x.008 1.10x.010
.900x.008 1.00x.008 1.10x.008
.900x.010 .900x.010 1.0x.010
.800x.006 .900x.008 1.00x.008
.800x.010 .800x.010 .900x.010
.700x.006 .800x.008 .900x.008
.700x.010 .700x.010 .800x.010
.620x.020 .700x.015 .800x.008
.625x.065 .625x.065 .700x.010
1.125x.093 .875x.090 .700x.015
.875x.090 .875x.090 .875x.090
.875x.090
Rebound Rebound Rebound
ADJUSTER
.800x.012 .800x.012 .800x.012

1.00x.025
Compression Compression Compression
N/A 1.00x.025 N/A
1.0x.025 1.0x.025 1.0x.025
.625x.065
1.0x.025 1.0x.025 1.0x.025
.625x.065 .625x.065 .625x.065

Shocks
2012 Front Track Shocks (FTS)
IN IN VOLUME
IN IN IN
7043634 12.34 8.84 3.5 .625 2.0

7043628 Walker Evans .75 200
11.75 8.21 3.54 .50
7043602 4.3
7043737 Fox 12.27 8.63 3.64 .498 .73 Full 250
7043738 Walker Evans 12.25 8.64 3.61 .625 2.25 200
7043720 Fox 11.67 8.33 3.34 .498 .74 250
7043722 Walker Evans 11.67 8.33 3.34 .625 2.25 200
2012 Front Track Shocks

SHOCK 7043737 7043738 7043720 7043722 7043634 7043628 7043602
.620x.093 .625x.065 .625x.065
.620x.093 .625x.065 .625x.065 .625x.065
.700x.008 .700x.008 .700x.008
.700x.008 .700x.008 .700x.010 .700x.008
.800x.008 .800x.008 .800x.008
REBOUND
.800x.008 .800x.008 .800x.010 .800x.008

.900x.008 .900x.008 .900x.008
.900x.008 .900x.008 .900x.010 .900x.008
1.0x.008 1.0x.008 1.0x.008
1.10x.008 1.00x.008 1.00x.010 1.00x.008
1.10x.008 1.10x.008 1.10x.008
1.25x.008 1.10x.008 1.10x.010 1.10x.008
1.25x.008 1.25x.012 1.25x.012
.800x.008 1.25x.010 1.25x.012 1.25x.010
.800x.008
1.25x.008
.900x.008
1.25x.010
1.25x.008
.900x.008
1.25x.010
1.25x.010 1.25x.012 1.25x.010
7
Piston
.070 .063 .070 .063 .086 .063 .063
Orifice
1.30x.012 1.30x.012
1.30x.010 1.30x.008 1.30x.010 1.30x.010
1.10x.012 1.30x.015 1.10x.012
1.25x.015 1.20x.008 1.10x.010 1.10x.010
1.0x.010 1.10x.015 1.0x.010
.900x.006 .900x.010 .900x.008 .900x.010
COMPRESSION
1.30x.010 .900x.006 1.30x.010

1.25x.015 1.30x.010 1.30x.012 1.30x.010
1.25x.008 1.25x.015 1.25x.008
1.25x.015 1.25x.010 1.25x.012 1.25x.010
1.10x.008 1.10x.015 1.10x.008
1.10x.012 1.10x.008 1.10x.010 1.10x.008
1.0x.008 1.0x.012 1.0x.008
1.0x.012 1.00x.008 1.00x.010 1.00x.008
.900x.008 .900x.012 .900x.008
.900x.012 .900x.008 .900x.010 .900x.008
.800x.008 .800x.012 .800x.008
.800x.012 .800x.008 .800x.010 .800x.008
.700x.008 .700x.012 .700x.008
.700x.012 .700x.008 .700x.008 .700x.008
.625x.065 1.125x.093 .625x.065
1.125x.093 .625x.065 .875x.090 .625x.065
.875x.095 .875x.095
Rebound Rebound
.800x.012 .800x.012
ADJUSTER
1.00x.025
Compression Compression
1.00x.025
N/A 1.0x.025 N/A 1.0x.025 N/A N/A
.900x.015
1.0x.025 1.0x.025
.625x.065
.900x.015 .900x.015
.625x.065 .625x.065

7.13
Shocks
2012 Rear Track Shocks (RTS)
STROKE IFP DEPTH
IN IN
IN IN IN
7043721 Fox 17.29 12.06 5.23 .498 2.26

7043723 17.25 12.0 5.25 .625 2.0
7043635 16.71 10.96 5.75 .50 2.25 Full 200
Walker Evans
7043629 .625 2.0
16.80 11.35 5.45
7043603 .50 6.25
2012 Rear Track Shocks

SHOCK 7043721 7043723 7043635 7043629 7043603
.625x.065 .625x.065 .625x.065
.620x.093 .875x.090
.700x.012 .700x.010 .700x.015
.700x.012 .700x.008
.800x.012 .800x.010 .800x.015
REBOUND
.800x.012 .800x.015
.900x.012 .900x.010 .900x.015
.900x.012 .900x.012
1.0x.012 1.00x.012 1.00x.015
1.0x.012 1.00x.010
1.10x.012 1.10x.012 1.10x.015
1.10x.015 1.10x.010
1.20x.012 1.25x.015 1.20x.012
1.25x.015 1.20x.010
1.25x.015 1.25x.015 1.25x.015
1.25x.015 1.25x.008
1.25x.015 1.25x.015 1.25x.015
Piston Orifice .093 .055 .086 N/A .069
Shaft Bleed N/A .086 N/A .082 N/A
1.30x.006
1.25x.006 1.30x.010 1.30x.008
1.30x.006 1.30x.008
.900x.010 1.20x.008 1.10x.010
.700x.012 1.25x.006
1.30x.008 1.00x.010 .900x.008
COMPRESSION
1.25x.008 .800x.012
1.20x.008 1.25x.012 1.30x.010
1.10x.008 1.25x.010
1.10x.008 1.20x.008 1.20x.010
1.0x.006 1.10x.010
.800x.008 1.10x.008 1.10x.010
.900x.006 1.00x.010
1.20x.008 1.00x.008 1.00x.010
.800x.006 .900x.010
1.0x.006 .900x.008 .900x.010
.700x.006 .800x.010
.900x.006 .800x.008 .800x.010
.620x.020 .700x.010
.800x.006 .700x.008 .700x.008
1.125x.093 .625x.065
.700x.006 .875x.065 .875x.090
.875.090
Rebound
.800x.012
ADJUSTER
1.10x.025 Rebound
Compression
1.10x.025 1.00x.025
N/A 1.0x.025 N/A
1.00x.025 1.00x.025
1.0x.025
.875x.090 .625x.065
.900x.015
.625x.065

Shocks
SHOCK MAINTENANCE Walker Evans Remote Reservoir / Piggyback
Shock Disassembly
Walker Evans Coil-Over Piggyback Shock
NOTE: Remote reservoir shock shown.
IMPORTANT: To prevent damage or marks to the

COMPRESSION KNOB shock, the use of soft jaws on a vise is recommended.
SCREW
O-RING
CAUTION
O-RING SHOCK CONTENTS UNDER HIGH PRESSURE.

ALWAYS WEAR SAFETY GLASSES WHEN
WORKING WITH SHOCKS.
O-RING
1. Clean and carefully remove shock from the
NEEDLE IFP
suspension.
SPRING RETAINER WEARBAND
IFP DEPTH
BLEED SCREW 2. Remove button head screw from reservoir cap (if
applicable).
SNAP RING
BUTTON SCREW
REBOUND STACK
CONVEX PISTON
WEARBAND
BUSHING
COMPRESSION STACK
7
O-RING SHAFT SPACER
U CUP SEAL
O-RING
D WIPER
3. Insert safety needle carefully and depressurize the

SHOCK ROD shock.

7.15
Shocks
4. Press the end cap into the reservoir to access the NOTE: Place the valve stack on a clean shop towel in
snap ring. case you have to move them. This will also help when
5. Remove the snap ring, then remove the cap from the assembling them back onto the shock rod.
body.
13. Inspect the valves for kinks, waves, pits or foreign

material.
6. Place the shock lower eyelet in a vise.
14. Inspect the piston wear band and replace if damaged
7. Loosen and remove the bearing cap from the shock. or worn.
8. Remove the used oil from the shock body.
NOTE: Insert the IFP tool (PN PS-45908) and cycle the
internal floating piston (IFP) a few times to purge the
shock oil from the reservoir.
9. Remove the IFP from the reservoir with the IFP tool
(PN PS-45908).
10. Clean and inspect ALL parts and replace worn out
parts if needed.
IMPORTANT: Seal kits are available and should be

installed at this time if seals or o-rings are damaged or
worn.
11. Place the shock rod in a vise so that the threaded part
is facing upward.
12. Place the valve stack on a clean shop towel in order
of removal.

Shocks
Walker Evans Remote Reservoir / Piggyback
Shock Assembly
CAUTION
SHOCK CONTENTS UNDER HIGH PRESSURE.

1. Secure the shock rod in a vise with the threads of the

rod facing up.
2. Place the compression valve stack on the rod in the

reverse order of disassembly.
3. Place the valve piston on top of the compression
stack. 5. Secure the shock body by its lower mount.
6. Set the compression damping adjustment selector to
position 1.
7. Fill the shock body and remote reservoir 1/2 full of
Walker Evans 5w shock oil (PN 2874522).
8. Apply a thin film of oil to the IFP o-ring and floating
wear band located on the shock rod piston.
9. Compress the wear band and insert the IFP into the
reservoir. Allow as much air as possible to escape as
you install the piston.
7
4. Place a new lock nut onto the shock rod. Torque the
new lock nut to specification.
=T
Lock Nut Torque: 14 ft-lb (19 Nm)
IMPORTANT: Do not over torque or damage to the

valve stack can occur. 10. Screw the IFP tool, PN PS-45908, into the IFP.
11. Hold or place the reservoir as low as possible on
remote reservoir shocks so the air will travel upward
as you slowly cycle the IFP up and down.
Be sure to bottom out the piston in the reservoir

body.
Allow time for the bubbles to dissipate.
Repeat the process until all the air has been

removed.

7.17
Shocks
12. Set the IFP so it is approximately 1/8 from the bottom IMPORTANT: Fast installation of the piston rod and
of the reservoir. Install the bleed screw. assembly may displace the internal floating piston
(IFP) from its original position. Performance issues
will be a result if the IFP is not in its specified position.
16. Tighten the cylinder head onto the shock body.

17. Verify the IFP is set at the specified depth. If not, verify
there is oil on top of the IFP, then open the bleed
screw.
18. Set the IFP to specification, then close the bleed
screw.
19. Pour out any remaining shock oil from the reservoir.
20. Install the cap making sure the o-ring does not flip-
over. Install the snap ring.
21. Charge the shock to the specified pressure.
22. Clean the shock of all oil reside and check for any
13. With the cylinder head assembly pushed down leaks.
against the valve piston, dip the piston assembly in 23. Install button screw onto the reservoir cap.
shock oil.
14. Fill the shock body with oil to the bottom of the threads.
Carefully insert the piston rod and valve assembly into
the cylinder.
Slightly oscillate the piston rod to allow the piston

to enter the shock body bore as it purges the air
out
Slight up and down movement may be required to

allow all the air to pass through the piston
assembly.
15. Slowly push the piston rod and assembly into the
shock body until the threads can be engaged.
NOTE: During installation, some shock oil will over

flow. Wrap a shop cloths around the shock body to
catch any oil overflow.

Shocks
FOX IFP Monotube Shock Disassembly Shock Components (Bearing Air Bleed)
BODY CAP
Shock Components (IFP Air Bleed)
BODY CAP
FILL PORT
FILL PORT
BLEED SCREW BLEED SCREW
O-RING
IFP DEPTH
O-RING
IFP DEPTH
IFP
WEARBAND
BLEED SCREW
O-RING O-RING
IFP
WEARBAND SPRING RETAINER

O-RING
SPRING RETAINER
LOCK NUT
REBOUND STACK BACKUP PLATE
SPRING GUIDE PISTON
REBOUND STACK
LOCK NUT
BACKUP PLATE
WEARBAND
7
COMPRESSION STACK
SPRING GUIDE PISTON TOP OUT PLATE
BEARING
WIPER
WEARBAND
COMPRESSION STACK O-RINGS
TOP OUT PLATE
BEARING ICE SCRAPER
WIPER
RETAINER
AIR VALVE/SET SCREW
O-RINGS
ICE SCRAPER
RETAINER
SHOCK ROD
SHOCK ROD
EYELET
BUSHING
EYELET
BUSHING

7.19
Shocks
Shock Disassembly FOX IFP Monotube Shock Assembly
Shock Assembly - IFP Air Bleed Shocks
CAUTION
SHOCK CONTENTS UNDER HIGH PRESSURE. CAUTION

WORKING WITH SHOCKS. SHOCK CONTENTS UNDER HIGH PRESSURE.
1. Remove the shock from the vehicle. Clean the shock WORKING WITH SHOCKS.
assembly to remove all dirt and foreign material.
Inspect the assembly for any noticeable signs of 1. Place the shock rod eyelet in the bench vise. Apply a
damage. liberal amount of shock oil to the surface of the shock
2. Clamp the body cap end of the shock in a soft-jawed rod and internal bore of the bearing.
bench vise.
3. Remove the bleed screw from the fill port. Insert the NOTE: Install jounce bumper if equipped.
needle of the gas fill tool, PN PS-45259, into the fill
port to depressurize the shock. Push the shock rod 2. Place the seal protector, PN 2201639, over the
down to ensure all nitrogen is expelled. Remove the threaded end of the shock rod. Carefully install the
fill port from the body cap. bearing onto the shock rod.
3. Install the topout plate, and compression valve stack.
4. Remove the bearing assembly from the shock body.
Use a Vernier Caliper and reference the valve stack
Remove the bearing assembly/shock rod from the
specifications in this chapter if unsure of the shim
shock body.
order of assembly.
5. Release the bench vise and drain all of the oil out of
4. Install a new wearband on the piston valve. Lubricate
the shock body into a suitable container. Discard the
the piston with shock oil. Install the piston with the
oil in accordances with local rules and regulations.
greater number of relief ports facing up away from the
6. Position the bearing cap end of the shock over a clean compression stack.
shop towel on the bench. Use compressed air applied
to the fill port bore to push the IFP out of the shock 5. Install the rebound valve stack. Again, if unsure of
body. order of shims, use a Vernier Caliper and reference
the valve stack specifications for the shock in this
7. Using the shock body holding tool, PN 2871071,
chapter.
clamp the shock body with the body cap pointed up
6. Install the backup plate. Remove the seal protector
in a bench vise. Remove the body cap from the tube.
and install a new lock nut. Torque lock nut to 15-20 ft-
8. Remove the lock nut from the shock rod. Remove the lb (20-27 Nm).
backup plate, rebound stack, piston, compression
stack, and top-out plates as one assembly. Orientate 7. Remove the shock rod from the bench vise. Secure
these components on a clean shop towel as they are the shock body with shock body holding tool in the
assembled on the shock rod. vise.
9. Remove the shock rod from the bearing. 8. Install the bearing/shock rod assembly into the body
tube. Tighten securely. Remove shock body from
10. With the shock disassembled, inspect all o-rings, vise. Secure shock rod eyelet in bench vise.
wiper, wearbands, and the ice scraper. It is
9. With the shock rod eyelet mounted in the vise, and the
recommended that all be replaced with new parts.
body cap end of the shock pointed up, slowly fill 3/4
11. Inspect the shock rod and shock body tube for of the body tube with new shock oil.
damage and/or pitting.
12. Inspect the rebound and compression stack valve
shims. Shims that are damaged, bent, chipped, or
Fox 5W Shock Oil
2870995(Quart)
wavy in appearance must be replaced.
13. Thoroughly clean all parts and dry with compressed
air. 10. Allow the oil to sit for several minutes to allow air
bubbles to escape. Gently tap on the shock body to
assist in removing any trapped air.

Shocks
11. After a few minutes, slowly and carefully pump the FOX IFP Monotube Shock Assembly
shock body up and down to force the oil through the
valves stacks and piston orifices. Continue until air Shock Assembly - Bearing Air Bleed Shocks
bubbles no longer rise to the surface of the oil.
12. After removing all of the air from the shock oil, collapse
the shock rod into the shock body. CAUTION
13. Remove the bleed screw from the IFP. Install a new
o-ring and wearband onto the IFP. Lubricate the SHOCK CONTENTS UNDER HIGH PRESSURE.
assembly with shock oil. ALWAYS WEAR SAFETY GLASSES WHEN
14. Set the depth of the IFP locator tool, PN 2871351, with
a Vernier Caliper. The IFP depth specifications are
noted for all rebuildable shocks in this chapter. 1. Place the shock rod eyelet in the bench vise. Apply a
15. Slowly push the IFP down into the shock body until the liberal amount of shock oil to the surface of the shock
IFP locator tool bottoms-out on the tube. Tap on the rod and internal bore of the bearing.
shock body to remove any air trapped under the IFP.
NOTE: Install jounce bumper if equipped.
NOTE: The IFP must be completely submerged in
shock oil to ensure air does not become trapped 2. Place the seal protector, PN 2201639, over the
under the IFP. threaded end of the shock rod. Carefully install the
bearing onto the shock rod.
16. With the IFP correctly set inside the tube, install the 3. Install the topout plate, and compression valve stack.
IFP bleed screw. Make sure not to move the shock rod Use a Vernier Caliper and reference the valve stack
after installing the screw as doing so will move the IFP. specifications in this chapter if unsure of the shim
17. Remove the shock from the bench vise and pour out order of assembly.
the remaining shock oil into a suitable container. 4. Install a new wearband on the piston valve. Lubricate
18. Install the body cap onto the shock body. Tighten
securely.
the piston with shock oil. Install the piston with the
greater number of relief ports facing up away from the 7
compression stack.
19. Reinstall the fill port. Charge the shock with nitrogen
to the specified pressure using the gas fill tool, PN PS- 5. Install the rebound valve stack. Again, if unsure of
45259. The shock rod should be pushed outwards as order of shims, use a Vernier Caliper and reference
the IFP compresses the shock oil. the valve stack specifications for the shock in this
chapter.
20. Remove the fill tool from the fill port and reinstall the
bleed screw. 6. Install the backup plate. Remove the seal protector
and install a new lock nut. Torque lock nut to 15-20 ft-
21. Test shock by pushing down on the shock rod. The rod
lb (20-27 Nm).
should extend slowly after pushing it into the tube with
no sound of trapped air inside the oil. If the sound of 7. Remove the shock rod from the bench vise. Secure
air is present or the rate of shock rod compression or the shock body with shock body holding tool in the
extension dramatically changes, the shock should be vise.
disassembled and the oil replaced. 8. With the body cap removed from the shock body, the
IFP must be installed as shown in the illustration.
Install a new o-ring and wearband onto the IFP.
Lubricate the assembly with shock oil.
9. Set the depth of the IFP locator tool, PN 2871351, with
a Vernier Caliper. The IFP depth specifications are
noted for all rebuildable shocks in this chapter.
10. Slowly push the IFP down into the shock body until the
IFP locator tool bottoms-out on the tube.
11. Install the gas fill port bleed screw into the body cap.
Install a new body cap o-ring, and then reinstall the
body cap. Tighten securely.
NOTE: The IFP should now be set in the correct

position inside the shock body.

7.21
Shocks
12. Mount the body cap end of the shock in bench vise.
Slowly fill 3/4 of the body tube with new shock oil.
Fox 5W Shock Oil

2870995(Quart)
13. Allow the oil to sit for several minutes to allow air
bubbles to escape. Gently tap on the shock body to
assist in removing any trapped air.
14. Install the shock rod/bearing cap assembly into the
shock body. Submerge the piston assembly in the
shock oil.
15. Slowly and carefully pump the piston up and down to
force the oil through the valves stacks and piston
orifices. Gently tap on the shock body to dislodge
trapped air. Continue until air bubbles no longer rise
to the surface of the oil.
NOTE: Pump the valve assembly slowly. Harsh and

abrupt movements may move the IFP.
16. After removing all of the air from the shock oil, fill the
shock body with oil. Again, remove any air bubbles
that may have formed.
17. Wrap a clean shop towel around the shock body to
catch oil that overflows. Carefully install the bearing
cap. Tighten the cap securely.
18. Charge the shock with nitrogen to the specified
pressure using the gas fill tool, PN PS-45259. The
shock rod should be pushed outwards as the IFP
compresses the shock oil.
19. Remove the fill tool from the fill port and reinstall the
bleed screw.
20. Test shock by pushing down on the shock rod. The rod
should extend slowly after pushing it into the tube with
no sound of trapped air inside the oil. If the sound of
air is present or the rate of shock rod compression or
extension dramatically changes, the shock should be
disassembled and the oil replaced.

Shocks
Walker Evans IFP Monotube Shock Shock Disassembly
O-RING CAUTION
FILL PORT SHOCK CONTENTS UNDER HIGH PRESSURE.

BODY CAP O-RING

BLEED SCREW
1. Remove the shock from the vehicle. Clean the shock
O-RING assembly to remove all dirt and foreign material.
Inspect the assembly for any noticeable signs of
damage.
O-RING
IFP 2. Clamp the body cap end of the shock in a soft-jawed
bench vise.
WEARBAND
3. Remove the bleed screw from the fill port. Insert the
needle of the gas fill tool, PN PS-45259, into the fill
port to depressurize the shock. Push the shock rod
down to ensure all nitrogen is expelled. Remove the
fill port from the body cap.
SPRING RETAINER
4. Remove the bearing assembly from the shock body.
Remove the bearing assembly/shock rod from the
IFP DEPTH
shock body.
5. Release the bench vise and drain all of the oil out of
LOCK NUT the shock body into a suitable container. Discard the
REBOUND STACK
PISTON VALVE
oil in accordances with local rules and regulations.
6. Position the bearing cap end of the shock over a clean
7
WEARBAND
REBOUND STACK
shop towel on the bench. Use compressed air applied
to the fill port bore to push the IFP out of the shock
BEARING
body.
O-RINGS
U-CUP SEAL WIPER NOTE: Body cap removal is only required if the
sealing o-ring is believed to be damaged. Final
assembly IFP depth is measured from the bearing end
of shock.
7. Remove the lock nut from the shock rod. Remove the
backup plate, rebound stack, piston, compression
SHOCK ROD
stack, and top-out plates as one assembly. Orientate
these components on a clean shop towel as they are
assembled on the shock rod.
8. Remove the shock rod from the bearing.
EYELET 9. With the shock disassembled, inspect all o-rings, the
BEARING
U-cup seal, wearbands, and the wiper seal. It is
recommended that all be replaced with new parts.
RETAINER
10. Inspect the shock rod and shock body tube for
damage and/or pitting.
11. Inspect the rebound and compression stack valve
shims. Shims that are damaged, bent, chipped, or
wavy in appearance must be replaced.
12. Thoroughly clean all parts and dry with compressed
air.

7.23
Shocks
Walker Evans IFP Monotube Shock 13. Allow the oil to sit for several minutes to allow air
Assembly bubbles to escape. Gently tap on the shock body to
assist with removing any trapped air.
Shock Assembly 14. Carefully install the shock rod/bearing into the shock
body. Have a clean shop towel in hand to wipe up any
oil that spills out of the shock. Submerge the piston
CAUTION valve assembly in the shock oil.
SHOCK CONTENTS UNDER HIGH PRESSURE. NOTE: From this point on, do not remove the piston
ALWAYS WEAR SAFETY GLASSES WHEN valve assembly from the shock oil.
15. Slowly and carefully stroke the shock rod up and down
1. Place the shock rod eyelet in the bench vise. Apply a to force the oil through the valve stacks and piston
liberal amount of shock oil to the surface of the shock orifices. Continue until air bubbles no longer rise to the
rod and internal bore of the bearing. surface of the oil. Tap on the shock body/rod to assist
2. Place the seal protector, PN 2201639, over the with the removal of any trapped air.
threaded end of the shock rod. Carefully install the 16. Completely fill the shock body with shock oil. Wrap the
bearing onto the shock rod. bearing and open end of shock with a clean shop
3. Install the topout plate, and compression valve stack. towel.
Use a Vernier Caliper and reference the valve stack 17. Slide the bearing down the rod shaft. Install the
specifications in this chapter if unsure of the shim bearing into the shock body and securely tighten. Oil
order of assembly. must spill out during installation to ensure air does not
4. Install a new wearband on the piston valve. Lubricate remain in the oil.
the piston with shock oil. Install the piston with the 18. Remove the fill port bleed screw. Charge the shock
greater number of relief ports facing away from the with nitrogen to 200 PSI using the gas fill tool, PN PS-
compression stack. 45259. The shock rod should be pushed outwards as
5. Install the rebound valve stack. Again, if unsure of the IFP is compresses the shock oil.
order of shims, use a Vernier Caliper and reference 19. Remove the fill tool from the fill port and reinstall the
the valve stack specifications for the shock in this bleed screw.
chapter. 20. Test shock by pushing down on the shock rod. The rod
6. Install the backup plate. Remove the seal protector should extend slowly after pushing it into the tube with
and install a new lock nut. Torque lock nut to 15-20 ft- no sound of trapped air inside the oil. If the sound of
lb (20-27 Nm). air is present or the rate of shock rod compression or
7. Remove the shock rod from the bench vise. Secure extension dramatically changes, the shock should be
the body cap with the open end of the tube facing up disassembled and the oil replaced.
into the bench vise.
8. Install a new o-ring and wearband onto the IFP.
Lubricate the assembly with new shock oil.
9. Install the IFP into the shock with the flat side facing
the body cap.
10. Set the depth of the IFP using a Vernier Caliper.
Reference the IFP depth specification for the shock in
this chapter.
11. With the IFP set, verify the fill port bleed screw is
installed. Doing so will prevent the IFP from moving
when stroking the shock rod in later steps.
12. Slowly fill 3/4 of the shock body with new shock oil.
Walker Evans 5W Shock Oil

2874522(Quart)

Steering and Suspensions
CHAPTER 8
OVERVIEW / SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.3
INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.3
ROD END INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.3
ROD END ENGAGEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.3
FRONT SUSPENSION TYPE BY MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.4
REAR SUSPENSION TYPE BY MODEL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.4
CAMBER / TOE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.4
SUSPENSION MOUNTING FASTENER TORQUE . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.5
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.5
INITIAL SHOCK SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.6
INDEPENDENT FRONT SUSPENSION (IFS) SHOCK SETTINGS. . . . . . . . . . . . . . . . .8.7
REBOUND ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.8
FRONT TRACK SHOCK (FTS) FACTORY SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . .8.9
REAR TRACK SHOCK (RTS) FACTORY SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . .8.10
LIMITER STRAPS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.11
TORSION SPRINGS/SAG SETTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.11
FRONT SUSPENSION ASSEMBLY ILLUSTRATIONS . . . . . . . . . . . . . . . . . . . . . . . . . 8.13
2010 PRO-RIDE FRONT CONTROL ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.13
2011 PRO-RIDE FRONT CONTROL ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.14
2012 PRO-RIDE (FIXED CAMBER) FRONT CONTROL ARMS . . . . . . . . . . . . . . . . . .8.15
PRO-RIDE RMK/WIDE ADJUSTABLE FRONT CONTROL ARMS . . . . . . . . . . . . . . . .8.16
2010-2011 RUSH UPPER STEERING ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . .8.17
2012 RUSH/SWITCHBACK UPPER STEERING ASSEMBLY . . . . . . . . . . . . . . . . . . . .8.18
SWITCHBACK ASSAULT UPPER STEERING ASSEMBLY . . . . . . . . . . . . . . . . . . . . .8.19
600/800 RMK UPPER STEERING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.20
600/800 PRO RMK/RMK ASSAULT UPPER STEERING ASSEMBLY . . . . . . . . . . . . .8.21
2010 RUSH LOWER STEERING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.22
2011-2012 RUSH/SWITCHBACK ASSAULT LOWER STEERING ASSEMBLY . . . . . .8.23
8
2011-2012 RMK STEERING ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.24
2010-2012 SWAY BAR ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.25
FRONT SUSPENSION SETTINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.26
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.26
ALIGNMENT BAR SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.26
MAXIMUM SETUP WIDTH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.26
HANDLEBAR CENTERING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.26
CAMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.27
CAMBER ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.27
TOE ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.28
DISASSEMBLY AND ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.29
SPINDLE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.29
SPINDLE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.29
SPHERICAL BEARING REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.29
UPPER/LOWER CONTROL ARM REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.29
UPPER/LOWER CONTROL ARM INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . .8.29

8.1
REAR SUSPENSION ASSEMBLY ILLUSTRATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . 8.30
2010 PROGRESSIVE 120 RAIL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.30
2010 PROGRESSIVE 120 RAIL FASTENER LOCATIONS. . . . . . . . . . . . . . . . . . . . . . 8.31
2010 PROGRESSIVE 120 FRONT TORQUE ARM ASSEMBLY . . . . . . . . . . . . . . . . . 8.32
2010 PROGRESSIVE 120 IDLER SHAFT ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . 8.33
2010 PROGRESSIVE 120 REAR CRANK/REAR SCISSOR ASSEMBLY . . . . . . . . . . 8.34
2010 PROGRESSIVE 120 REAR BUMPER/CLOSEOFF ASSEMBLY . . . . . . . . . . . . . 8.35
PROGRESSIVE 121 RAIL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.36
PROGRESSIVE 121 RAIL FASTENER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 8.37
PROGRESSIVE 121 FRONT TORQUE ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.38
PROGRESSIVE 121 IDLER SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.39
PROGRESSIVE 121 REAR CRANK/REAR SCISSOR ASSEMBLY . . . . . . . . . . . . . . . 8.40
2011 PROGRESSIVE 121 BUMPER/CLOSEOFF ASSEMBLY . . . . . . . . . . . . . . . . . . 8.41
2011 PROGRESSIVE 121 REAR MID FLAP COVERS. . . . . . . . . . . . . . . . . . . . . . . . . 8.42
PROGRESSIVE 136 RAIL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.43
PROGRESSIVE 136 RAIL FASTENER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . 8.44
PROGRESSIVE 136 FRONT TORQUE ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.45
PROGRESSIVE 136 IDLER SHAFTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.46
PROGRESSIVE 136 REAR CRANK/REAR SCISSOR ASSEMBLY . . . . . . . . . . . . . . . 8.47
2012 PROGRESSIVE 121/136 BUMPER/CLOSEOFF ASSEMBLY . . . . . . . . . . . . . . . 8.48
2012 PROGRESSIVE 121/136 REAR MID FLAP COVERS . . . . . . . . . . . . . . . . . . . . . 8.49
RMK 144/SWITCHBACK ASSAULT PIVOTS/REAR IDLER . . . . . . . . . . . . . . . . . . . . . 8.50
RMK144/SWITCHBACK ASSAULT RAIL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . 8.51
RMK 144/SWITCHBACK ASSAULT RAIL FASTENER LOCATIONS . . . . . . . . . . . . . . 8.52
RMK 144/SWITCHBACK ASSAULT FRONT/REAR TORQUE ARM. . . . . . . . . . . . . . . 8.53
PRO RMK 155/163 PIVOTS/REAR IDLER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.54
PRO RMK 155/163 RAIL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.55
PRO RIDE RMK 155/163 RAIL FASTENER LOCATIONS . . . . . . . . . . . . . . . . . . . . . . 8.56
PRO RMK 155/163 FRONT TORQUE ARM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.57
PRO RMK 155/163 REAR TORQUE ARM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.58
PRO-RIDE PROGRESSIVE SUSPENSION OPERATION . . . . . . . . . . . . . . . . . . . . . . . 8.59
OPERATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.59
ADJUSTMENT PROCEDURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.59
REAR TRACK SHOCK THRUST BEARING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.63
PROGRESSIVE REAR SUSPENSION REMOVAL AND INSTALLATION . . . . . . . . . . . 8.64
REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.64
INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.65
REAR CRANK SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.65
REAR TRACK SHOCK SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.66
RMK COIL-OVER REAR SUSPENSION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.67
SUSPENSION ADJUSTMENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.67
RMK COIL-OVER STANDARD SPRINGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.67
HEAVY DUTY REAR TRACK SHOCK SPRING-RMK COIL-OVER . . . . . . . . . . . . . . . 8.68
MEASURING REAR TRACK SHOCK SPRING INSTALLED LENGTH . . . . . . . . . . . . . 8.68
SPRING RETAINER SPANNER WRENCH . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.68
FINE TUNING ADJUSTMENTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.69
SHOCK DAMPENING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.69
RAIL SLIDERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.70
WEAR LIMIT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.70
REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.70
BREAK-IN. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8.70

OVERVIEW / SPECIFICATIONS Rod End Installation
All rod ends in the front suspension and steering
Inspection
assemblies (including steering drag links) must be parallel
When inspecting steering and suspension components for with the corresponding mating surface after they are
wear or damage, always replace parts as necessary. installed and torqued to specification.
Refer to the assembly exploded views in this chapter for
identification of components and torque values of If the rod ends are not parallel, the rider may experience
fasteners. Make notes of the direction a bolt goes through an increase in ski darting and/or bump steer.
a part, what type of nut is used in an application, etc.
Always use genuine Polaris parts and hardware when PARALLEL

replacing front end components. Review steering
adjustment guidelines before making adjustments.
The following components must be inspected at this time.
Tie rods and tie rod ends PARALLEL

PARALLEL
Sway bar and bushings/linkage (where applicable)
Handlebars and steering post assembly
Spindles and bushings
Skis and skags
Pitman arms / Idler arms
A-arms and bushings
Shock absorbers, shock mounts, springs
All related fasteners - check torque.
Pivot shafts and bushings
Rod End Engagement
Always follow rod end engagement guidelines. Maximum

Rod ends must engage the rod a minimum of 2x the thread 8
diameter when adjustment is complete.
setup width must be checked whenever front suspension
components are adjusted or replaced. Example: .4375 (11mm) rod end (A) X 2 = minimum
thread engagement (B) .875 (22mm).

8.3
Front Suspension Type by Model Camber / Toe Specifications
Maximum width and camber measurements are achieved
FRONT SUSPENSION MODELS with the front end elevated and shocks at full extension.
2010-2011Rush/ Toe alignment is measured at ride height. This means that
Pro-Ride
Switchback Assault the machine is on the ground and resting at normal ride
2012 Rush/Switchback/ height, not full rebound. Measure at a point 10 (2.54cm)
Pro-Ride (Fixed Camber) forward of the ski mount bolt and 10 (2.54cm) behind the
Switchback Assault
ski mount bolt, preferably on the center line of the carbide
Pro-Ride RMK Adjustable RMK/Pro RMK skags.
Pro-Ride Wide Adjustable RMK Assault
Maximum width is measured from the center of the
spindles.
Rear Suspension Type by Model
Camber measurement is taken from the top of the
REAR SUSPENSION MODEL alignment bar to the top of the ski mount hole in the spindle
with the bushing removed.
Pro-Ride Progressive 120 2010 Rush
NOTE: Only models featuring upper control arms
Pro-Ride Progressive 121 Rush with rod ends allow for adjusting camber.
Pro-Ride Progressive 136 Switchback
Camber & Toe Specifications
Switchback 144 Switchback Assault
RMK/Pro RMK/RMK MAXIMUM TOE OUT
RMK Coil Over 155/163 SET UP CAMBER (At ride
Assault SUSPENSION
WIDTH in/cm in/cm height)
( .25in/.6cm) in/cm
1.68 .31
Pro-Ride
(4.2 0.8)
Pro-Ride 41.52/105
(Fixed N/A
Camber) 0 -.12
(0 -0.305)
Pro-Ride RMK 1.95 0.31
36.26/92
Adjustable (4.3 0.8)
Pro-Ride Wide 38.58/98 2.25 0.31

Adjustable (5.7 0.8)

Suspension Mounting Fastener Torque
NOTE: Reference assembly illustrations for torque
specifications not listed in table.
Torque
Component
Specification
Upper/Lower Control Arm Bulkhead Nuts 30 ft-lb (41 Nm)
Upper/Lower Spindle-to-Control Arm Fasteners 40 ft-lb (54 Nm)
Steering Rack Link Fastener Torque 37 ft-lb (50 Nm)
Tie Rod-to-Spindle Fastener Torque 37 ft-lb (50 Nm)
IFS Shock Upper/Lower Fastener Torque 37 ft-lb (50 Nm)
Ski Fastener Torque 37 ft-lb (50 Nm)
Sway Bar Linkage Fasteners 20 ft-lb (27 Nm)
Sway Bar Bushing Block Fasteners 7 ft-lb (10 Nm)
Lower Steering Shaft Bushing Block Fasteners

2010 14.7 ft-lb (20 Nm)
2011-Current 22 ft-lb (30 Nm)
Lower Steering Shaft-to-Bulkhead Fastener Nut 22 ft-lb (30 Nm)
Drag Link Rod End Fasteners 37 ft-lb (50 Nm)
Upper Steering Shaft Bushing Block Fasteners

2010 15 ft-lb (20 Nm)
2011-Current 20 ft-lb (27 Nm)
Handlebar Riser/Clamp Fasteners 14.7 ft-lb (20 Nm)
120/121/136 Front Torque Arm Tunnel Fasteners

60 ft-lb (80 Nm)
120/121/136 Rear Crank Tunnel Fasteners 60 ft-lb (80 Nm)
120/121/136 Rear Track Shock Fasteners 33 ft-lb (45 Nm)
120/121/136 Rear Track Shock Reservoir Clamp

Fasteners
17 ft-lb (23 Nm) 8
120/121/136 Rear Scissor-to-Rear Crank Fasteners 33 ft-lb (45 Nm)
120/121/136 Rear Scissor-to-Rail Fasteners 60 ft-lb (80 Nm)
120/121/136 Upper Carrier Wheel Shaft Fasteners 33 ft-lb (45 Nm)
120/121/136 Front Track Shock Fasteners 33 ft-lb (45 Nm)
Rear Idler Wheel Shaft Fasteners 33 ft-lb (45 Nm)
Switchback 144 FTA-to-Tunnel Fasteners 45 ft-lb (61 Nm)
Switchback 144 RTA-to-Tunnel Fasteners 45 ft-lb (61 Nm)
Switchback 144 Limiter Strap Mount Fasteners 12 ft-lb (16 Nm)
Switchback 144 Rear Idler Shaft Screws 35 ft-lb (47.4 Nm)
RMK Coil-Over FTA-to-Tunnel Fasteners 46 ft-lb (63 Nm)
RMK Coil-Over RTA-to-Tunnel Fasteners 46 ft-lb (63 Nm)
RMK Coil-Over Rear Idler Screws

33 ft-lb (44.7 Nm)
Special Tools
NOTE: Polaris dealers can order the tools listed in
this chapter through the SPX Service Tools catalog
or by calling SPX @ 1-800-328-6657.

8.5
Initial Shock Settings NOTE: A collumn for the RTS spring setting is not
included as all vehicles require rider weight to set
Use the Initial Shock Settings Table below to set the the spring length/SAG setting. This information is
vehicle suspension to the original factory configuration. located within this chapter.
Initial Shock Settings

IFS SPRING FTS SPRING
IFS SPRING IFS CLICKER FTS SPRING
INSTALLED INSTALLED FTS CLICKER RTS CLICKER
MODEL PRELOAD SETTING PRELOAD
LENGTH LENGTH SETTING SETTING
(INCHES/CM) (REBOUND) (INCHES/CM)
(INCHES/CM) (INCHES/CM)
2010 Rush 3.75/9.5 .75/1.9

N/A N/A 2 4
2011 Rush 4.5/11.4 1.0/2.54
6
2011 800 SB
10/25.4 7.25/18.4 8 8
Assault
2011 800 RMK 10.5/26.7 N/A N/A Screw
2011 800 RMK N/A N/A
10.75/27.3 6 6
Assault
8.5/21.6 N/A
2011 800 PRO
10.25/26
RMK N/A N/A
2012 Rush Base 3.25/8.25
2012 Rush
2.875/7.3 6
PRO-R
2 4
2012 Rush 6
3.25/8.25 N/A
PRO-R LE (8)
2012 SB Base 3.25/8.25 N/A 1.0/2.54 N/A N/A N/A
2012 SB ADV.
600 3.25/8.25 N/A N/A 4
800 2.875/7.3 6 2 4
2012 SB
2.875/7.3 6 2 4
PRO-R
2012 800 SB
10/25.4 6 7.25/18.4 8 8
Assault
2012 600/800
RMK
10.5/26.7 N/A Screw
144
155 N/A N/A N/A N/A
2012 600/800
10.25/26 N/A
PRO RMK
8.5/21.6
2012 800 RMK
10.75/27.3 6 6 6
Assault

Independent Front Suspension (IFS) Shock
Settings
To change the IFS shock preload/installed spring height, MEASURING PRELOAD
raise the front of the snowmobile up and off the ground to
remove the weight from the front suspension. Grasp the
spring and rotate it. Increasing IFS shock spring preload B
too much may adversely affect the handling of the
snowmobile and the performance of both the front and
rear suspensions. Never exceed one inch (2.54 cm) of
adjustment beyond the factory setting.
When decreasing IFS shock spring preload, make sure at

least two turns of preload are holding the spring retainer
against the spring. Failure to do so may cause the retainer
to fall out when the shock is fully extended.
A
MEASURING PRELOAD
MEASURING INSTALLED LENGTH
8
A

8.7
Adjusting the IFS shock spring preload raises or lowers
the front vehicle ride height and either increases or
decreases ski pressure when not accelerating. Increasing
spring preload will also shift the vehicle balance towards
the rear. Decreasing the spring preload will lower the front
vehicle ride height and shift the vehicle balance towards
the front.
The compression dampeners control ride comfort/quality.

Turning the adjusters towards the SOFT setting (counter-
clockwise) will make the ride quality less harsh, but may
cause the shocks to bottom out. Turning the adjuster
towards the STIFF setting (clockwise) will make the ride
quality stiffer.
Make equal adjustments to both shocks and only one to

two clicks at a time. Heavier riders may want to set the
compression clickers two to four clicks higher than lighter
riders.
Rebound Adjustment
Rush 800 LE models feature IFS shocks with rebound
adjusters.
The rebound adjustment clicker is located at the bottom of

the shock rod. There are 16 possible settings. The initial
factory setting is 8 clicks.
Make equal adjustments to both shocks and only one to

two clicks at a time.
Turning the clicker clockwise (inwards) increases

rebound control and the shock will extend slower
after being compressed.
Turning the clicker counter-clockwise (outwards)
decreased rebound control and the shock will
extend faster after being compressed.

Front Track Shock (FTS) Factory Settings
To change the FTS spring preload, carefully tip the
snowmobile onto its left side to remove weight from the
front track shock. Grasp the spring and rotate it.
2011-2012 RUSH/SWITCHBACK/RMK2010
ASSAULT
RUSH
When decreasing FTS spring preload, make sure at least

two turns of preload are holding the spring retainer against
the spring. Failure to do so may cause the retainer to fall
out when the shock is fully extended.
When the snowmobile is not accelerating, Increasing FTS

spring preload will decrease ski pressure. Decreasing
FTS spring preload will increase ski pressure.
The compression dampener controls ride comfort/quality.

Turning the adjuster towards the SOFT setting (counter-
clockwise) will make the ride quality less harsh, but may
cause the FTS to bottom out. Turning the adjuster towards
the STIFF setting (clockwise) will make the FTS stiffer.
8
MEASURING PRELOAD
2010 RUSH

8.9
Rear Track Shock (RTS) Factory Settings
The RTS spring is the primary suspension setup and
tuning component. For more information regarding how to
set the spring preload and compression dampening,
reference the Pro-Ride Progressive Suspension or Pro-
Ride RMK Coil-Over Rear Suspension sections in this
chapter.
RMK COIL OVER
2011-2012 RUSH/SWITCHBACK

Limiter Straps The specified SAG setting for the Switchback 144 Tipped
rear suspension is 5" (12.7cm). to set SAG, follow these
The limiter straps on the Pro-Ride Progressive and Pro- steps:
Ride RMK Coil-Over rear suspensions are not adjustable.
Drilling new holes in the straps to increase or decrease 1. Position the snowmobile on snow.
strap length is not recommended. NOTE: Positioning the snowmobile on a hard
surface (pavement/concrete) distributes more
The limiter straps on Switchback/RMK 144 rear weight to the rear track shock/torsion springs and
suspensions are adjustable. The limiter straps are initially can distort the following measurements.
set in the mid position.
2. Lift the rear bumper to fully extend the rear
suspension. Using a tape measure, find (X).
X
HIGH
MID
LOW
3. Have the rider, in riding gear, mount the snowmobile.

The rider should drop down hard on the seat and
Move BOTH limiter straps to the HIGH position to increase bounce the suspension several times to collapse the
ski pressure and reduce ski lift. The HIGH position moves suspension.
the balance of the snowmobile towards the front which 4. Again, measure the distance between the rear
increases cornering characteristics, but reduces flotation. bumper and ground (Y).
8
Move BOTH limiter straps to the LOW position to decrease
ski pressure and increase ski lift. The LOW position moves
the balance of the snowmobile towards the rear which
increases traction and flotation, but reduces cornering
characteristics.
Torque limiter strap nuts to specification.

Y
=T
Limiter Strap Fasteners: 19 ft-lb (25 Nm)
Torsion Springs/SAG Setting 5. Subtract measurement Y from X (X-Y=SAG).

The Switchback 144 rear suspension is equipped with rear
torsion springs. The spring preload can be set by adjusting
the torsion spring preload blocks.
The torsion spring preload sets the rear suspension SAG

setting. SAG is the difference between the unloaded and
loaded rear bumper height when the snowmobile is sitting
on snow.

8.11
6. Set both torsion spring adjuster blocks to SOFT,
MEDIUM, or FIRM to achieve the specified SAG
measurement.
SOFT
MEDIUM
FIRM
NOTE: Optional torsion springs are available to fine

tune SAG setting. See individual model
specifications in Chapter 1.

FRONT SUSPENSION ASSEMBLY ILLUSTRATIONS
2010 Pro-Ride Front Control Arms
MOUNTING STUDS PIVOT SHAFTS
BUSHINGS
C UPPER CONTROL ARM

C
MOUNTING STUDS
C
D
C
C
BUSHINGS
A B
C
B
SPINDLE
LOWER CONTROL ARM
SPHERICAL BEARING BUSHING

WASHERS
SNAP RING
A
BUSHINGS 8
CAUTION
Never re-use lock nuts. Always re-assemble using new

lock nuts.
=T
A: 37 ft-lb (50 Nm) (Shock Mounting Fastener Nuts)
B: 40 ft-lb (54 Nm)
C: 30 ft-lb (41 Nm)
D: 44 ft-lb (60 Nm) Apply Loctite 262 to Threads
NOTE: Assembly Notes

Orientate rod ends so they are parallel with mating
component.
Apply grease to pivot shafts during assembly.

8.13
2011 Pro-Ride Front Control Arms
PIVOT SHAFTS
MOUNTING STUDS
C
C
BUSHINGS
C
C
UPPER CONTROL ARM
SPRING WASHERS
MOUNTING STUDS
C
D
C
C
BUSHINGS B
A B
SPINDLE
B
LOWER CONTROL ARM
BUSHINGS
SPHERICAL BEARING
WASHERS
SNAP RING
BUSHINGS
CAUTION

lock nuts.
=T
B: 40 ft-lb (54 Nm)
C: 30 ft-lb (41 Nm)

component.

2012 Pro-Ride (Fixed Camber)
Front Control Arms
MOUNTING STUDS
BUSHINGS
C
SNAP RING
PIVOT SHAFTS
C
SPHERICAL BEARING
C
WASHERS
MOUNTING STUDS C
UPPER CONTROL ARM
C B
PIVOT SHAFTS
C
BUSHINGS
C B
A B SPINDLE
LOWER CONTROL ARM
SPHERICAL BEARING
SNAP RING
BUSHINGS
WASHERS
A
BUSHINGS
8
CAUTION

lock nuts.
=T
B: 40 ft-lb (54 Nm)
C: 30 ft-lb (41 Nm)

component.

8.15
Pro-Ride RMK/Wide Adjustable
Front Control Arms
MOUNTING STUDS
C
C BUSHINGS
PIVOT SHAFTS C
C UPPER CONTROL ARM
SPRING WASHERS
MOUNTING STUDS
PIVOT SHAFTS D
C
C
BUSHINGS C
A
B
B
LOWER CONTROL ARM SPINDLE
BUSHINGS
SPHERICAL BEARING
A WASHERS
SNAP RING
BUSHINGS
B
CAUTION

lock nuts.
=T
B: 40 ft-lb (54 Nm)
C: 30 ft-lb (41 Nm)

component.

2010-2011 Rush Upper Steering Assembly
B HANDLEBAR COVER
HANDLEBAR HOOK
A
HANDLEBAR CLAMPS
INSTALL CLAMP BUSHINGS

HERE
RISER
POST CLAMPS B
HANDLEBAR HOOK
HANDLEBAR CLAMPS
C
CLAMP BUSHINGS A
A
C
STEERING POST
APPLY GREASE TO BUSHINGS PRIOR TO ASSEMBLY
8
HAND GUARDS/MOUNTS

CAUTION Install handlebar riser with FWD facing front of
vehicle.
lock nuts.
=T
A: 14.7 ft-lb (20 Nm)
B: 12 ft-lb (16 Nm)
C: (2010) = 15 ft-lb (20 Nm)
C: (2011) 20 ft-lb (27 Nm)
Throttle Lever Block Screw: 35 in-lb (4 Nm)
Master Cylinder Screws: 24 in-lb (2.7 Nm)
Torque hand guard screws to prevent components
from moving/rotating during operation. DO NOT
CRUSH HANDLEBAR WHEN TORQUING SCREWS.

8.17
2012 Rush/Switchback
Upper Steering Assembly
INSTALL CLAMP BUSHINGS AS SHOWN

WITH OFFSETS DOWN.

vehicle.
lock nuts.
=T
A: 14.7 ft-lb (20 Nm)
B: 12 ft-lb (16 Nm)
C: 15 ft-lb (20 Nm)
Torque hand guard screws to prevent components
from moving/rotating during operation. DO NOT
CRUSH HANDLEBAR WHEN TORQUING SCREWS.

Switchback Assault Upper Steering
Assembly
HANDLEBAR CLAMPS
B
HANDLEBAR HOOK
POST CLAMPS
CLAMP BUSHINGS
C
8
APPLY GREASE TO BUSHINGS PRIOR TO ASSEMBLY
STEERING POST
CAUTION

lock nuts.
=T
A: 14.7 ft-lb (20 Nm)
B: 12 ft-lb (16 Nm)
C: 20 ft-lb (27 Nm)
Master Cylinder Clamp: 60-80 in-lb (6.8-9 Nm)
DO NOT CRUSH HANDLEBAR WHEN TORQUING
SCREWS.

8.19
600/800 RMK Upper Steering Assembly
HANDLEBAR COVER
MOUNTAIN BAR
D
D
A
B
HANDLEBAR CLAMPS
HANDLEBAR HOOK
RISER
HANDLEBAR CLAMPS
CLAMP BUSHINGS
STEERING STRAPS
CLAMP BUSHINGS
BUSHING SPACERS
C STEERING POST

vehicle.
lock nuts.
=T
A: 14.7 ft-lb (20 Nm)
B: 12 ft-lb (16 Nm)
C: 18 ft-lb (25 Nm)
D: 5 ft-lb (7 Nm)
SCREWS.

600/800 PRO RMK/RMK Assault Upper
Steering Assembly
MOUNTAIN BAR
HANDLEBAR CLAMPS
B
HANDLEBAR HOOK
D STEERING STRAP
CLAMP BUSHINGS
8
STEERING STRAP
BUSHING SPACERS
D
STEERING POST
CAUTION

lock nuts.
=T
A: 14.7 ft-lb (20 Nm)
B: 12 ft-lb (16 Nm)
C: 5 ft-lb (7 Nm)
D: 18 ft-lb (25 Nm)
Master Cylinder Clamp: 60-80 in-lb (6.8-9 Nm)
SCREWS.

8.21
2010 Rush Lower Steering Assembly
B
UPPER STEERING POST
C UPPER DRAG LINK

BUSHINGS
D ROD END
POST BRACKET
B B
FIXED LINK LOWER STEERING POST
C
ROD END
B
TIE ROD
B
C RETAINING RING
BEARING
BUSHING REDUCER SPACER STUD
BEARING RETAINING RING
SPACER B A
IDLER ARM B
BEARING B
BUSHING REDUCER
ROD END
TIE ROD B
C
C
ROD END
TIE ROD BOOT

CAUTION Orientate rod ends so they are parallel with mating
component.
lock nuts. Tie rod end-to-rod end (center-to-center) length
=15.04" (382mm)
Upper drag link rod end-to-rod end (center-to-
=T center) length = 11.71" (297.5mm)
A: 22 ft-lb (30 Nm)
B: 37 ft-lb (50 Nm)
C: 11 ft-lb (15 Nm)
D: 14.7 ft-lb (20 Nm)

2011-2012 Rush/Switchback/
SwitchbackAssault Lower Steering
Assembly
UPPER STEERING POST
B
FIXED DRAG LINK
POST CAP
STEERING POST BUSHINGS
B LOWER STEERING POST

A
FIXED LINK
B
BUSHING SPACERS
ROD END B RETAINING RING

C TIE ROD BEARING
SPACER STUD
RETAINING RING
B
A
BUSHING REDUCER C B
BEARING
SPACER B
B
BEARING IDLER ARM ROD END C

BUSHING REDUCER TIE ROD
B 8
C
TIE ROD BOOT
BUSHING ROD END

CAUTION Orientate rod ends so they are parallel with mating
component.
lock nuts. Tie rod end-to-rod end (center-to-center) length
=15.04" (382mm)
=T
A: 22 ft-lb (30 Nm)
B: 37 ft-lb (50 Nm)
C: 11 ft-lb (15 Nm)

8.23
2011-2012 RMK/PRO RMK/RMK Assault
Steering Assembly
UPPER STEERING POST

B
C ROD END
C UPPER DRAG LINK
POST CAP
STEERING POST BUSHINGS
B
A LOWER STEERING POST
FIXED LINK
BUSHING SPACERS
ROD END C
B
WASHERS TIE ROD
B RETAINING RING
BEARING
C
B SPACER STUD
A RETAINING RING
B
BUSHING REDUCER B
BEARING B
SPACER C
IDLER ARM
BEARING ROD END
BUSHING REDUCER
TIE ROD
TIE ROD BOOT C ROD END

BUSHING
WASHERS
B
CAUTION
Never re-use lock nuts. Always re-assemble using new Orientate rod ends so they are parallel with mating
lock nuts. component.
Tie rod end-to-rod end (center-to-center) length =
=T 800 RMK/PRO RMK - 13.4" (354mm)
800 RMK Assault - 15.04" (382mm)
A: 22 ft-lb (30 Nm) Upper drag link rod end-to-rod end (center-to-
B: 37 ft-lb (50 Nm) center) length = 15.19" (385.9mm)
C: 11 ft-lb (15 Nm)

2010-2012 Sway Bar Assembly
SWAY BAR
BUSHINGS
BUSHING BRACKET
A
A B
LINK
8
B
CAUTION

lock nuts.
=T
A: 7.4 ft-lb (10 Nm)
B: 20 ft-lb (27 Nm)

8.25
FRONT SUSPENSION SETTINGS Maximum Setup Width
The maximum width setting is the distance between the
Overview
front center lines of both spindles with the skis off the
The following topics are outlined involving the front ground and the shocks installed.
suspension:
Because of the design of the front suspension, maximum
Maximum Width width can only be changed by adjusting camber. This is
Handlebar Centering due to the fact that only the upper control arms feature rod
Setting Camber ends and thus camber can only be adjusted by turning the
Ski Toe Adjustment upper control rod ends in or out.
Before making any adjustments to the front suspension, 1. To measure the maximum setup width, raise the front
inspect all components for damage. Replace any broken, of the snowmobile off the ground with the shocks and
bent or worn components before making any adjustments. skis installed.
2. Center the skis/spindles. Measure the distance
Verify the sway bar and related hardware are not bent, between the spindle center lines.
loose, or broken. Inspect the shocks.
The shocks on the front suspension are the only

components that limit maximum control arm extension.
Bent shock rod(s) adversely affect front suspension
settings and handling.
Never install longer (when fully extended) shocks.

Installing longer shocks will stress the upper control arm
rod ends and lower control arm spherical bearings. MAXIMUM SETUP WIDTH
Always verify track alignment. Proper track alignment is

critical when aligning the skis with the chassis.
Rod ends must be parallel with mating components. Rod = In./cm.

ends that are not parallel will increase the bump steer
effect.
Maximum Width
An alignment bar is an essential tool required to set Pro-Ride = 41.52/105
camber. Pro-Ride RMK Adjustable = 36.26/92
Pro-Ride Wide Adjustable = 38.58/98
Alignment Bar Specifications 3. If the measurement is out of specification, inspect the
DIAMETER: .623-.625 (15.824-15.875mm) front suspension for damage. Replace damaged
LENGTH: 45 (114.3cm) components.
MATERIAL: C-1018 4. If no damage is found, reset the camber.
Polaris PN: 5333508 (Order from tool vendor.)
Handlebar Centering
1. Raise the vehicle to remove the skis.
2. Verify the handlebars are straight. Measure from each
bar end to a common center point at the rear of the
vehicle.
3. Verify the steering drag link is not damaged, bent, or
loose. If it is, the drag link must be either adjusted or
replaced. If the drag link is correct, adjust the steering
linkage tie rod ends until handlebar is centered. Note
that the toe setting will require adjustment.
4. Reinstall the spindle rod ends, bushings, and skis.
Torque bolts to specification.

Camber 4. Insert the alignment bar, PN 5333508 or equivalent,
through one spindle. Adjust the opposing spindles
On a snowmobile, camber is the angle of the spindle upper control arm rod end to adjust the angle of the
relative to vertical as viewed from the front. The camber spindle.
angle becomes increasingly more negative as the control
5. Check the measurement between the top-end of the
arms deflect upward.
alignment bar and the top of the spindles bushing/ski
bolt hole (see illustration below).
0 = Neutral Camber. The spindle is perpendicular
UPPER CONTROL ARM ROD END NUT
to the ground.
+ = Positive Camber. The top of the spindle is
canted outward from the chassis.
- = Negative Camber. The top of the spindle is
canted inward towards the chassis.
- 0 +
BUSHING / BOLT HOLE
CAMBER SETTING DISTANCE
ALIGNMENT BAR
6. Insert the alignment bar into the opposite spindle and

perform the same steps. Monitor the specified camber
measurement as the control arm rod end nuts are
Camber Adjustment
adjusted.
7. Continue making small rod end changes to both
control arm rod end nuts until the camber setting
= In./cm. specification is achieved at both spindles.
Camber Setting
Top of alignment bar to top of ski bushing / bolt spindle
CAUTION 8
hole.
DO NOT EXCEED THE MAXIMUM SETUP WIDTH
Pro-Ride = 1.68.31/420.8
SETTING WHEN ADJUSTING CAMBER.
Pro-Ride RMK Adjustable = 1.95 0.31/4.3 0.8
Pro-Ride Wide Adjustable = 2.25 0.31/5.7 0.8 8. Verify the upper rod ends are torqued to specification.
Ensure the rod ends remain parallel to the spindles
1. Verify the handlebars are centered. Measure from when torquing nuts.
each end to a common center point at the rear of the
9. Apply a liberal amount of Premium Grease to the ski
snowmobile if necessary.
bushings, and then reinstall the bushings and skis.
2. Raise the front of the snowmobile off the ground.
Torque fasteners to specification.
Remove the skis and ski bushings.
3. Verify the shocks are at full extension and that no IFS
components are bent or damaged. Replace any
component that is damaged before making any
adjustments.

8.27
Toe Adjustment 10. Turn both tie rods equally to set ski toe. When
finished, measurement (X) should be 0" - 1/8" wider
Toe is adjusted with the shocks and skis installed. Track than measurement (Y).
alignment must be correct before starting this process.
11. Torque steering tie rod jam nuts to specification and
lower the vehicle.
Toe alignment is measured at ride height.
1. Rock the front end of the vehicle up and down and

then set it down gently. This will set the front
suspension at ride height.
2. Verify the handlebars are centered. Measure from
each end to a common center point at the rear of the
snowmobile to verify.
3. Measure and make a mark 10 (2.54cm) forward of
the ski mount bolt and 10 (2.54cm) behind the ski
mount bolt, preferably on the center line of the carbide
skags.
4. Place a straight edge along the one side of the track.

Make sure that the straight edge is touching along the
length of the track.
5. Record the measurements from the edge of the
straight edge to the forward ski mark (X) and the
rearward ski mark (Y).
6. Adjust the tie rod so that both measurements are the
same.
7. Place the straight edge on the opposite side of the
track and measure the opposite ski marks.
8. Adjust the tie rod so that both measurements are the
same.
9. Steps 3 to 8 will align the skis with the track. At this
point, verify the handlebar is centered with the skis.
NOTE: The handlebar can be aligned with the skis
on models featuring an adjustable drag link by
adjusting the length of the drag link. If the
snowmobile does not feature an adjustable drag
link, handlebar-ski alignment can only be performed
by adjusting the steering tie rod lengths.

DISASSEMBLY AND ASSEMBLY Upper/Lower Control Arm Removal
1. Remove the fastener securing the control arm to the
Spindle Removal
spindle. Remove the lower shock fastener.
1. Securely support the front of the machine up off the 2. Remove the nuts securing the control arm to the
floor. bulkhead.
2. Remove the ski(s). 3. Remove the control arm, pivot bushings, and pivot
3. Remove the upper control arm (UCA)-to-spindle shafts.
fastener.
4. Remove the fastener securing the lower control arm Upper/Lower Control Arm Installation
(LCA) to the spindle. Note the orientation of the
1. Replace the upper or lower control arm bushings in
fastener and nut.
the control arm(s).
5. Remove the tie rod from the spindle, by removing the 2. Replace the upper or lower control arm(s) into the
nut and bolt. bulkhead.
3. Reference the front suspension illustration for the
Spindle Assembly appropriate fastener torque.
1. Assembly is the reverse order of disassembly.
Reference the front suspension assembly illustration
for fastener torque values.
Spherical Bearing Replacement

1. Remove the fastener securing the lower control arm
(LCA) to the spindle.
2. Remove the lower shock fastener.
3. Remove the nuts securing the LCA to the bulkhead.
4. Remove the snap ring, then, using a press, press the
spherical bearing out of the LCA.
5. Press in a new bearing, then install the snap ring.
6. Assemble the LCA into the spindle, and shock into
LCA. Reference front suspension assembly 8
illustration for fastener torque values.

8.29
REAR SUSPENSION ASSEMBLY ILLUSTRATIONS
2010 Progressive 120 Rail Assembly
TRACK TENSIONER BRACKET
INSIDE OF RAIL
E
RAIL BUMPER
D D
C BOGIE WHEEL ASM.
RAIL TIP B
RAIL SLIDER
A METRIC FASTENERS
=T
A: 7.4 ft-lb (10 Nm)
B: 4 ft-lb (5.4 Nm)
C: Torque nut until screw protrudes 7/32" (5.3mm)
D: 17 ft-lb (23 Nm)
E: 33 ft-lb (45 Nm)
Assembly Notes
Never re-use lock nuts. Always replace with new

parts.
All pivots must rotate freely after tightening
fasteners.
CAUTION
Some rail shaft fasteners are pre-coated with locking

agent. Never re-use these fasteners once removed.
Always use new pre-coated fasteners.

2010 Progressive 120 Rail Fastener Locations
F K
A B
E J
D I
C
H
G
LEFT RAIL SHOWN
Components/Fasteners:
A - Rail Tip
B - Limiter Strap Shaft
C - Rail Bumper
D - H Bracket/Bogie Wheel Shaft
E - Bogie Wheel Asm. (Mount to outside of rail).
F - Front Torque Arm Shaft
G - Bogie Wheel Asm. (Mount to inside of rail).
H - Rail Brace Shaft
I - Rear Pivot Shaft 8
J - Rail Brace Shaft
K - Rear Idler Adjuster Block

8.31
2010 Progressive 120 Front Torque Arm Assembly
C INNER SHAFT
SPACERS
FTS CARRIER WHEELS
FRONT TORQUE ARM
PIVOT SHAFTS
BUSHINGS BUSHINGS
B
B
UPPER TORQUE ARM SHAFTS
BUSHINGS
LIMITER STRAPS
A
INSTALL STRAPS RUBBER SIDE OUT METRIC FASTENERS
=T
A: 17 ft-lb (23 Nm)
B: 60 ft-lb (80 Nm) Apply Loctite 262 to Threads
C: 33 ft-lb (45 Nm)
D: 60 ft-lb (80 Nm)
Assembly Notes

parts.
fasteners.
CAUTION


2010 Progressive 120 Idler Shaft Assembly
H BRACKET REAR IDLER WHEELS

WHEEL SPACERS INNER SHAFT
SPACER
A
A
SHAFT ADJUSTER BLOCK
A
B
SHAFT
A
A A A
SHAFT
A
METRIC FASTENERS
8
=T
A: 33 ft-lb (45 Nm)
B: 60 ft-lb (80 Nm)
Assembly Notes

parts.
fasteners.
Install rear idler adjust blocks with flat side facing
adjuster screw.
CAUTION


8.33
2010 Progressive 120 Rear Crank/Rear
Scissor Assembly
REAR TRACK SHOCK
BUSHING
REAR CRANK
B
BUSHING
PLUGS
BUSHING
UPPER CARRIER WHEEL ASM. A
BUSHINGS
BUSHINGS
A
REAR PIVOT
B
B
BUSHINGS
METRIC FASTENERS
=T fasteners.
A: 33 ft-lb (45 Nm)

CAUTION
B: 60 ft-lb (80 Nm)
Assembly Notes Some rail shaft fasteners are pre-coated with locking
Never re-use lock nuts. Always replace with new Always use new pre-coated fasteners.
parts.

2010 Progressive 120 Rear Bumper/Closeoff Assembly
REAR BUMPER
A
REAR PIVOT
A
MID FLAP
UPPER FLAP
REAR FLAP
CLOSEOFF FLAP
METRIC FASTENERS
=T
A: 7 ft-lb (9.5 Nm)
Assembly Notes

parts.
fasteners.

8.35
Progressive 121 Rail Assembly
INSIDE OF RAIL
E
SUPPORT PLATE
RAIL BUMPER SPACER
TRACK TENSIONER BLOCK

BUMPER LINER
D
C BOGIE WHEEL MOUNT
RAIL TIP B BOGIE WHEEL ASM.
RAIL SLIDER
A METRIC FASTENERS
=T
A: 7.4 ft-lb (10 Nm)
B: 4 ft-lb (5.4 Nm)
C: Torque nut until screw protrudes 5mm
D: 17 ft-lb (23 Nm)
E: 33 ft-lb (45 Nm)
Assembly Notes

parts.
fasteners.
CAUTION


Progressive 121 Rail Fastener Locations
A
O
I J
D G N
M
B
C
F L
E H K
LEFT RAIL SHOWN
A - Rail Tip
C - Rail Bumper
D - Left Rail Front Holes - Bogie Wheel Asm.
(Mount to outside of rail).
E - Right Rail Rear Holes - Bogie Wheel Asm.
F - Front Shock Shaft
G - Left Rail Front Holes - Bogie Wheel Asm.
(Mount to outside of rail). 8
H - Right Rail Rear Holes - Bogie Wheel Asm.
I - Front Torque Arm Shaft
J - Left Rail Front Holes - Bogie Wheel Asm.
(Mount to inside of rail).
K - Right Rail Rear Holes - Bogie Wheel Asm.
(Mount to inside of rail).
L - Rail Brace Shaft
M - Rear Pivot Shaft
N - Rail Brace Shaft
O - Rear Idler Adjuster Block

8.37
Progressive 121 Front Torque Arm
C
FRONT TRACK SHOCK
BUSHING
BUSHING
PIVOT SHAFT
BUSHING FRONT TORQUE ARM
A
B
LIMITER STRAPS
LIMITER STRAP SPACER INSTALL STRAPS RUBBER SIDE OUT METRIC FASTENERS
=T
A: 17 ft-lb (23 Nm)
B: 60 ft-lb (80 Nm) Apply Loctite 262 to Threads
C: 33 ft-lb (45 Nm)
Assembly Notes

parts.
fasteners.
CAUTION


Progressive 121 Idler Shafts
REAR IDLER WHEELS WASHER

ADJUSTER SPACER
INNER SHAFT
A SPACER
INSTALL TORQUE ARM A

BOLT IN THIS DIRECTION
A
SHAFT
ADJUSTER SPACER
B SHAFT
A A
INNER SHAFT
A
SPACERS A
WASHERS
ANODIZED SHAFT C
B
A
METRIC FASTENERS
8
=T
A: 33 ft-lb (45 Nm) Apply Loctite 262 to threads
B: 50 ft-lb (67 Nm) Apply Loctite 262 to threads
C: 60 ft-lb (81 Nm)
Assembly Notes

parts.
fasteners.
adjuster screw.
CAUTION


8.39
Progressive 121 Rear Crank/Rear Scissor Assembly
CRANK BUSHINGS
REAR CRANK
B CRANK BUSHINGS
PIVOT BUSHINGS
BUSHING PLUG
CRANK BUSHINGS
A
B
SPACER BUSHING
PIVOT BUSHINGS
WASHER
WASHER
A
SPACER
REAR PIVOT
B A
BUSHING
PIVOT SHAFTS
BUSHING
WASHERS B
METRIC FASTENERS
=T
A: 33 ft-lb (44.7 Nm)
B: 60 ft-lb (80 Nm)
Assembly Notes
CAUTION
parts.
All pivots must rotate freely after tightening agent. Never re-use these fasteners once removed.
fasteners. Always use new pre-coated fasteners.

2011 Progressive 121 Bumper/Closeoff Assembly
REAR FLAP
B
MID FLAP
A A
MID FLAP COOLER
REAR BUMPER
A
A C
REAR PIVOT
METRIC FASTENERS
=T
A: 33 ft-lb (44.7 Nm)
B: 3.6 ft-lb (5 Nm)
C: 9.5 ft-lb (7 Nm)
Assembly Notes

parts.
fasteners.

8.41
2011 Progressive 121 Rear Mid Flap Covers
CLOSEOFF FLAP
UPPER FLAP
UPPER FLAP PLATE

Progressive 136 Rail Assembly
INSIDE OF RAIL
RAIL BUMPER
SUPPORT PLATE SPACER
TRACK TENSIONER BLOCK

BUMPER LINER
D
C
BOGIE WHEEL ASM.
RAIL TIP
B
D
BOGIE WHEEL MOUNT
RAIL SLIDER
A METRIC FASTENERS
=T
8
A: 7.4 ft-lb (10 Nm)
B: 4 ft-lb (5.4 Nm)
C: Torque nut until screw protrudes 5mm
D: 17 ft-lb (23 Nm)
E: 33 ft-lb (45 Nm)
Assembly Notes

parts.
fasteners.
CAUTION


8.43
Progressive 136 Rail Fastener Locations
A Q
I P
D G J
O
B
C
L
E F H K M N
LEFT RAIL SHOWN
A - Rail Tip
C - Rail Bumper
D - Left Rail Front Holes - Bogie Wheel Asm.
(Mount to outside of rail)
E - Right Rail Rear Holes - Bogie Wheel Asm.
F - Front Shock Shaft
G - Left Rail Front Holes - Bogie Wheel Asm.
H - Right Rail Rear Holes - Bogie Wheel Asm.
I - Front Torque Arm Shaft
J - Left Rail Front Holes - Bogie Wheel Asm.
(Mount to inside of rail)
K - Right Rail Rear Holes - Bogie Wheel Asm.
L - Rail Brace Shaft
M - Bogie Wheel Asm.
N - Rail Brace Shaft
O - Rear Pivot Shaft
P - Rail Brace Shaft
Q - Rear Idler Adjuster Block

Progressive 136 Front Torque Arm
FRONT TRACK SHOCK

C
BUSHING
BUSHING
PIVOT SHAFT
FRONT TORQUE ARM

BUSHING
A
B
LIMITER STRAPS
LIMITER STRAP SPACER
INSTALL STRAPS RUBBER SIDE OUT METRIC FASTENERS
=T
8
A: 17 ft-lb (23 Nm)
C: 33 ft-lb (45 Nm)
Assembly Notes

parts.
fasteners.
CAUTION


8.45
Progressive 136 Idler Shafts
REAR IDLER WHEELS

ADJUSTER SPACER WASHER
INNER SHAFT
A SPACER
INSTALL TORQUE ARM A

BOLT IN THIS DIRECTION
A
A SHAFT ADJUSTER SPACER
SHAFT
B SHAFT A
A
A
A
INNER SHAFT
SPACERS A
WASHERS
ANODIZED SHAFT C
B
A
METRIC FASTENERS
=T
A: 33 ft-lb (45 Nm) Apply Loctite 262 to threads
C: 60 ft-lb (81 Nm)
Assembly Notes

parts.
fasteners.
adjuster screw.
CAUTION


Progressive 136 Rear Crank/Rear Scissor
Assembly
CRANK BUSHINGS
REAR CRANK
B CRANK BUSHINGS
PIVOT BUSHINGS
BUSHING PLUG
CRANK BUSHINGS
A
B
SPACER BUSHING
PIVOT BUSHINGS
WASHER
WASHER
A
SPACER
REAR PIVOT
B A
BUSHING
8
PIVOT SHAFTS
BUSHING
WASHERS B
METRIC FASTENERS
=T fasteners.
A: 33 ft-lb (44.7 Nm)

CAUTION
B: 60 ft-lb (80 Nm)
parts.

8.47
2012 Progressive 121/136 Bumper/Closeoff
Assembly
REAR FLAP
B MID FLAP
B
A
A MID FLAP COOLER
REAR BUMPER
A
C
A
REAR PIVOT
METRIC FASTENERS
=T
A: 33 ft-lb (44.7 Nm)
B: 3.6 ft-lb (5 Nm)
C: 9.5 ft-lb (7 Nm)
Assembly Notes

parts.
fasteners.

2012 Progressive 121/136 Rear Mid Flap
Covers
CLOSEOFF FLAP
UPPER FLAP
UPPER FLAP PLATE

8.49
RMK 144/Switchback Assault
Pivots/Rear Idler
WASHER
A SPACER
REAR IDLER WHEEL
INNER SHAFT
SPACER
A
RMK REAR IDLERS
A REAR PIVOT
INNER SHAFT
A
A A
B INNER SHAFT
A REAR TRACK SHOCK PIVOT
WASHERS
SPACERS
INNER SHAFT
SHAFT
B
A STANDARD FASTENERS
=T
A: 35 ft-lb (47.4 Nm)
B: 35 ft-lb (47.4 Nm) Apply Loctite 262
Assembly Notes

parts.
fasteners.
Install rear idler adjust spacers with flat side facing
adjuster screw.
CAUTION


RMK144/Switchback Assault Rail Assembly
TENSIONER BLOCK
JAM NUT
C
E
INSIDE OF RAIL
RMK 144 ONLY RAIL BUMPER
A
A
D SWITCHBACK ASSAULT ONLY

D
RAIL BUMPER
RAIL BRACE
BUMPER INSERT
D
SPRING GUIDE
C
B
RAIL TIP
BOGIE WHEEL MOUNT
BOGIE WHEEL ASM.

RAIL SLIDER D
DOMED WASHER
A
STANDARD FASTENERS
=T
8
A: 3-6 ft-lb (4-8 Nm)
B: 4 ft-lb (5.4 Nm)
C: Torque nut until screw protrudes 7/32" (5.3mm)
D: 19 ft-lb (25 Nm)
E: 35 ft-lb (47 Nm)
Assembly Notes

parts.
fasteners.
CAUTION


8.51
Rail Fastener Locations
A F M
G
D I L
N
B C
E H K
J
LEFT RAIL SHOWN
A - Rail Tip
C - Rail Bumper
D - Bogie Wheel Asm. (Mount to outside of rail).
E - Front Shock Shaft
F - Front Torque Arm Shaft/Screw
G - Torsion Spring Guide
H - Rear Track Shock Front Pivot Shaft
I - Bogie Wheel Asm. (Mount to inside of rail).
J - Rail Brace Asm. (Switchback Assault Only -
Mount to outside of rail).
K - Rear Pivot Shaft
L - Bogie Wheel Asm. (Mount to outside of rail).
M - Rear Idler Adjuster Block
N - Rail Rumper (RMK 144 Only)

Front/Rear Torque Arm
FRONT TORQUE ARM
PIVOT SHAFT
B
INNER SHAFT
C A
A INNER SHAFT
BUSHING
REAR PIVOT
D B
LIMITER STRAP
INSTALL STRAPS RUBBER SIDE OUT
E
BUSHINGS
CARRIER WHEEL
LIMITER STRAP SLEEVES
2012 SWITCHBACK ASSAULT ONLY
BUSHING
E
SPRING ADJUSTER
COLLAR
SHOCK ROD
TORSION SPRING
STANDARD FASTENERS
=T 8
A: 45 ft-lb (61 Nm)
B: 19 ft-lb (25 Nm)
C: 12 ft-lb (16 Nm)
D: 25 ft-lb (34 Nm)
E: 35 ft-lb (47.4 Nm)
Assembly Notes

parts.
fasteners.
CAUTION


8.53
RMK/PRO RMK 155/163 Pivots/Rear Idler
IDLER SPACER WASHER

IDLER WHEEL
WASHER SPACER
C
WASHER
REAR PIVOT
C
INNER SHAFT
C BRACE SHAFT
IDLER SPACER
C
D
C
WASHER C
C
B INNER SHAFT
RMK ASSAULT ONLY
A
SPACERS (FLAT SIDE UP)
WASHERS
C
SHOCK SHAFT
LIMITER STRAP SHAFT B

A
METRIC FASTENERS

=T fasteners.
A: 33 ft-lb (44.7 Nm) - Apply Loctite 262

CAUTION
B: 46 ft-lb (63 Nm)
C: 33 ft-lb (44.7 Nm)
D: 6 ft-lb (8 Nm) Some rail shaft fasteners are pre-coated with locking
Assembly Notes Always use new pre-coated fasteners.

parts.

RMK/PRO RMK 155/163 Rail Assembly
ADJUSTER BLOCK
JAM NUT
ADJUSTER SCREW
BUMPER
BUMPER LINER
B
INSIDE OF RAIL
BUMPER
BUMPER LINER C
B SCRATCHER ASM.
RAIL TIP
A OPTION FOR 800 RMK
RAIL SLIDER
BOGIE WHEEL MOUNT
D
BOGIE WHEEL
8
DOMED WASHER
METRIC FASTENERS

=T fasteners.
A: 4 ft-lb (5.5 Nm)

CAUTION
B: Torque until 5mm of threads protruded from nut.
C: 31 ft-lb (42 Nm)
D: 17 ft-lb (23 Nm) Some rail shaft fasteners are pre-coated with locking
Assembly Notes Always use new pre-coated fasteners.

parts.

8.55
RMK/PRO Ride RMK 155/163 Rail Fastener
Locations
G N
A M
C D H K
F I
B
E J L
LEFT RAIL SHOWN

NOTE: 163 Rail Shown. 155/155 Assault Similar
A - Rail Tip
C - Rail Bumper
D - Bogie Wheel Asm. (Mount to outside of rail)
E - Front Shock Shaft
F - Scratchers (Optional on 800 RMK)
G - Front Torque Arm Shaft/Screw
H - Bogie Wheel Asm. (Standard on 800 RMK.
Optional for all other models. Mount to inside of
rail on all models except for 800 RMK Assault)
I - Rail Bumper
J - Rail Brace Shaft/Screws (Standard on 800
RMK Assault)
K - Bogie Wheel Asm. (Standard on 800 RMK.
Optional for all other models. Mount to outside of
rail)
L - Rear Scissor Shaft/Screw
M - Rail Brace Shaft/Screws
N - Rear Idler Adjuster Block
IMPORTANT: RMK Assualt Models - If installing

accessory bogie wheels, the wheels MUST be
installed on the outside of the rails at location (H) and
the scratchers must be removed.
Damage to the front track shock reservoir will occur if
the accessory bogie wheels are installed on the inside
of the rail.

RMK/PRO RMK 155/163 Front Torque Arm
FRONT TRACK SHOCK
BUSHING
REAR TRACK SHOCK FRONT PIVOT
BUSHING
B
A
GREASE ZERKS
BUSHING
FRONT TORQUE ARM
GREASE ZERK PIVOT SHAFT

PIVOT SHAFT
B
LIMITER STRAP
A
B
RMK ASSAULT ONLY
BUSHING
INSTALL STRAPS RUBBER SIDE OUT

8
METRIC FASTENERS

=T fasteners.
A: 46 ft-lb (63 Nm)

CAUTION
B: 17 ft-lb (23 Nm)
parts.

8.57
RMK/PRO RMK 155/163 Rear Torque Arm
BUSHING
B
INNER SHAFT
A COLLAR
B
GREASE ZERK
BUSHING
CARRIER WHEEL
GREASE ZERK
GREASE ZERK REAR PIVOT
PIVOT SHAFT
BUSHING
A
BUSHING
SHOCK ROD
B
B
GREASE ZERK BUSHING
REAR TRACK SHOCK PIVOT
METRIC FASTENERS

=T fasteners.
A: 46 ft-lb (63 Nm)

CAUTION
B: 17 ft-lb (23 Nm)
parts.

PRO-RIDE PROGRESSIVE Adjustment Procedures
SUSPENSION OPERATION Always adjust the Pro-Ride Progressive suspension
following these three steps:
Operation
The Pro-Ride progressive suspension allows the rider to 1. Set the rear track shock spring preload for the rider
easily adjust the desired amount of weight transfer, ski weight in everyday street clothes, not riding gear.
pressure, and ride comfort using the following 2. Adjust fine tune the balance of the snowmobile
components: based on rider preference by increasing or decreasing
the rear track spring preload.
Rear track shock spring preload 3. Adjust the shock compression dampeners to tune ride
quality. Increase the compression dampening to
Rear track shock compression dampener
stiffen the ride. Decrease the compression
Front track shock spring preload dampening to soften the ride.
Front track shock compression dampener STEP 1 - REAR TRACK SHOCK SPRING PRELOAD
IFS shock compression dampeners
1. The rear track shock spring preload is set to the
IFS shock spring preload riders weight in everyday clothing, not riding gear.
2. Using the spring gauge tool supplied with the vehicle,
Unlike other Polaris rear suspensions, the Pro-Ride set the spring preload.
progressive rear suspension is not coupled and does not
NOTE: Lifting up on the seat support will remove the
feature front or rear-rear scissor stops. The front torque
load on the shock spring, making spring adjustment
arm is not linked with the rear crank or rear scissor.
easier.
Weight transfer during acceleration is controlled by two 3. If the shock threads are dirty or the preload knob is
primary factors. The first weight transfer control is the rear difficult to turn, spray the threads with Shock Thread
track shock spring preload. The second weight transfer Spray Lubricant, PN 2878018.
control is rider position. 4. Place the spring gauge tool on top of the shock with
the narrow end against the spring retainer knob.
Increasing rear track shock spring preload reduces 5. Reference where the silver shock body meets the red
weight transfer during acceleration and increases shock end cap. Turn the spring preload adjuster knob
ski pressure in all driving modes in or out until the weight call out on the gauge is 8
Sitting or standing close to the fuel tank decreases aligned with the silver-meets-red parting line.
weight transfer and increases ski pressure in all
driving modes
Decreasing rear track shock spring preload
increases weight transfer during acceleration and
decreases ski pressure in all driving modes
Sitting or standing at the rear of the seat increases
weight transfer under acceleration and decreases
ski pressure in all driving modes
Ride comfort is controlled by the compression dampener

adjusters on the IFS, and front/rear track shocks. All 2010 Tool Shown
shocks offer sixteen compression dampening settings.
6. A tape measure can be used to set the spring preload
Increasing shock dampening reduces bottoming,
when a gauge is not available, or an accessory rear
but makes the ride stiffer
track shock spring is installed in place of the standard
Decreasing shock dampening makes the ride spring.
softer, but increases the chance the suspension 7. Reference the Spring Guide Table when using a tape
will bottom-out measure for all springs.

8.59
2010-2011 RTS Spring Guide All of the springs, spring gauge tools, and spring preload
measurements using a tape measure are provided in the
The stock rear track spring is a 190#/inch spring. The RTS Spring Guide Table below.
stock spring will accommodate most riders weighing
between 120 and 250 lbs. (54-113 kg). NOTE: Use a tape measure in the same manner as a
gauge tool with the end of the tape against the
Two additional accessory springs are available for riders spring tension adjuster knob and the preload
whose weight is at the lowest or highest settings for the measurement length at the shock-body cap parting
190 spring. line.
2010-2011 RTS Spring Guide Table

STOCK 190 SPRING 120 LWT SPRING 260 HD SPRING
120 - 250 LBS. 90 - 155 LBS. 240+ LBS.
SPRING PN =
2010=7043572-385 SPRING PN = 7041575-385 SPRING PN = 7043585-385
2011 = 7043572-133
STOCK SPRING GAUGE PN LWT SPRING GAUGE PN HD SPRING GAUGE PN
2010 = 5253792 2010 = 5253854 2010 = 5253855
2011 = 5254748 2011 = 5254749 2011 = 5254750
Rider Weight Preload Rider Weight Preload Rider Weight Preload
lbs. kg in. cm lbs. kg in. cm lbs. kg in. cm
2 5/8 6.7 2 5/8 6.7 2 3/8 6.0
120 54 90 41 240 109
MIN MIN MIN MIN MIN MIN
130 59 2 3/4 7.0 95 43 2 3/4 7.0 255 116 2 1/2 6.3
140 64 2 7/8 7.3 100 45 2 7/8 7.3 270 122 2 5/8 6.7
150 68 3 7.6 105 48 3 7.6 280 127 2 3/4 7.0
160 73 3 1/8 7.9 110 50 3 1/8 7.9 295 134 2 7/8 7.3
170 77 3 1/4 8.3 115 52 3 1/4 8.3 310 141 3 7.6
180 82 3 3/8 8.6 120 54 3 3/8 8.6 320 145 3 1/8 7.9
3 1/4 8.3
190 86 3 1/2 8.9 125 57 3 1/2 8.9 335 152
MAX MAX
200 91 3 5/8 9.2 130 59 3 5/8 9.2
210 95 3 3/4 9.5 135 61 3 3/4 9.5
220 100 3 7/8 9.8 140 64 3 7/8 9.8
230 104 4 10.1 150 68 4 10.1
4 1/8 10.5
240 109 4 1/8 10.5 155 70
MAX MAX
4 1/4 10.8
250 113
MAX MAX
CAUTION
DO NOT ADJUST SPRING PRELOAD PAST THE MINIMUM

OR MAXIMUM SETTINGS LISTED FOR EACH SPRING.

2012 RTS Spring Guide All of the springs, spring gauge tools, and spring preload
measurements using a tape measure are provided in the
The stock spring will accommodate most riders weighing RTS Spring Guide Table below.
between 120 and 260 lbs. (54-118 kg).
NOTE: Use a tape measure in the same manner as a
Two additional accessory springs are available for riders gauge tool with the end of the tape against the
whose weight is at the lowest or highest settings for the spring tension adjuster knob and the preload
stock spring. measurement length at the shock-body cap parting
line.
2012 RTS Spring Guide Table

STOCK SPRING 120 LWT SPRING 260 HD SPRING
120 - 260 LBS. 90 - 155 LBS. 240+ LBS.
SPRING PN =
RUSH = 7043195-133 SPRING PN = 7041575-385 SPRING PN = 7043585-385
Switchback = 7043160-133
STOCK SPRING GAUGE PN
LWT SPRING GAUGE PN = N/A HD SPRING GAUGE PN = N/A
9923267
Rider Weight Preload Rider Weight Preload Rider Weight Preload
lbs. kg in. cm lbs. kg in. cm lbs. kg in. cm
2 5/8 6.7 2 3/8 6.0
1 1/2 3.81 90 41 240 109
120-140 54-64 MIN MIN MIN MIN
MIN MIN
95 43 2 3/4 7.0 255 116 2 1/2 6.3
100 45 2 7/8 7.3 270 122 2 5/8 6.7
140-160 64-73 1 3/4 4.44
105 48 3 7.6 280 127 2 3/4 7.0
110 50 3 1/8 7.9 295 134 2 7/8 7.3
160-180 73-82 2 5.08
115 52 3 1/4 8.3 310 141 3 7.6
8
120 54 3 3/8 8.6 320 145 3 1/8 7.9
180-200 82-91 2 1/8 5.39 3 1/4 8.3
125 57 3 1/2 8.9 335 152
MAX MAX
130 59 3 5/8 9.2
200-220 91-100 2 1/4 5.71
135 61 3 3/4 9.5
140 64 3 7/8 9.8
220-240 100-109 2 1/2 6.35
150 68 4 10.1
4 1/8 10.5
2 3/4 6.98 155 70
240-260 109-118 MAX MAX
MAX MAX
CAUTION
DO NOT ADJUST SPRING PRELOAD PAST THE MINIMUM

OR MAXIMUM SETTINGS LISTED FOR EACH SPRING.

8.61
STEP 2 - FINE TUNE THE BALANCE For example, riders wanting less inside ski lift during
cornering, but maximum traction during acceleration can
RIDER ACTIVE
shift their body position/weight towards the front and into
the turn and then shift their body position/weight rearward
SPRING PRELOAD
when exiting and accelerating out of the turn.
Likewise, riders who use a less active riding position may

want to only adjust the rear track spring preload to achieve
similar results.
Remember that while the Pro-Ride progressive rear

BALANCE
suspension can be adjusted to satisfy all types of riders
MORE TRACTION MORE SKI PRESSURE and riding styles, it is unlikely that one riders setup will
LESS SKI PRESSURE LESS TRACTION provide similar results for a different rider.
The Pro-Ride Progressive rear suspension allows the Always reset the rear track shock preload and shock
rider to fine tune the balance of the snowmobile depending compression dampening settings when a new driver rides
on the drivers riding style and trail conditions. Balance the snowmobile.
control is accomplished both mechanically and by the
driver. KEY POINTS/RECOMMENDATIONS
Mechanical balance adjustment involves increasing or Increasing rear track shock spring preload shifts
decreasing the rear track spring preload from the base the snowmobile balance forward
setting established in step one. Fine tuning the balance Decreasing rear track shock spring preload shifts
should only be done after riding the snowmobile. the snowmobile balance rearward
Adjustments should always be performed in small Always begin suspension setup by setting the rear
increments. track shock spring preload to the riders weight in
everyday street clothes.
NOTE: Turn the spring adjuster one full turn at a Make small adjustments when tuning the
time and then ride the snowmobile taking note of suspension settings
any changes. Ride the snowmobile after making each change
and take note of the results of each change
Increasing spring preload one full revolution at a time will Make ride position and weight distribution (sit at
shift the snowmobile balance to the front and result in the rear of the seat or close to the fuel tank, lean
increased ski pressure with less weight transfer for flatter into turns, etc.) changes while riding and take note
cornering and more precise steering. of the results
Ride the snowmobile on various trail conditions
Riders who sit or stand at the rear of the seat or experience and take note of the results
push through corners may want to increase rear track Adjusting spring preload controls balance,
spring preload. adjusting the compression or rebound (if
equipped) clickers controls comfort
Decreasing spring preload one full revolution at a time will Verify the track tension is set to specification
shift the snowmobile balance to the rear and result in
decreased ski pressure with more weight transfer during STEP 3 - ADJUSTING RIDE COMFORT/QUALITY
acceleration.
NOTE: Step 3 applies to shocks equipped with
Riders who sit or stand close to the fuel tank, when riding compression and/or rebound adjusters.
on loose snow with little traction, or when steering effort is
too high may want to decrease rear track shock spring After performing steps one and two, the last step in
preload. adjusting the snowmobiles suspension is to adjust the
ride comfort.
Rider-active balance control involves adjustments in rider
position and/or rider weight distribution when turning, Ride comfort/quality is controlled by the remote shock
encountering bumps/road approaches, or during compression dampeners.
acceleration/braking. Rider-active balance control can
effect the snowmobile balance just as much as adjusting
the rear track spring preload.

NOTE: Use the compression dampeners to control The thrust bearing can be installed on 2010 models
suspension bottoming, not the spring preload (equipped with original Walker Evans Shocks) by installing
adjusters. the following parts:
Spring Retainer - 5137540
Turning the compression adjuster knobs clockwise will Thrust Bearing - 3514706
increase resistance to bottoming, making the shock stiffer. Thrust Bearing Retainer - 5137541
X-Brace (Indy Red) - 1017977-293 (Not Shown)
Turning the compression adjuster knobs counter-
clockwise decreases resistance to bottoming, making the
shock softer. SPRING RETAINER
REAR TRACK SHOCK CLICKER
THRUST BEARING
IFS SHOCK CLICKERS THRUST BEARING RETAINER
FRONT TRACK SHOCK CLICKER
RIDE EXPERIENCE ADJUSTMENT The addition of the thrust bearing on a 2010 Rush
increases spring preload and requires the use of either a
Turn adjuster knobs clockwise tape measure or the 2011 spring gauge tools to set the
one click at a time. RTS spring length.
IFS shocks bottom out
Set both IFS shocks to the same
setting. The 2010 tools can also be trimmed to 150.46mm as
Turn front track shock shown below.
Front of rear suspension 2010 GAUGE TOOL 2011 GAUGE TOOL
compression adjuster knob
bottoms out
clockwise one click at a time.
Turn rear track shock
Rear of rear suspension
compression knob clockwise
bottoms out
one click at a time. 8
No bottoming, but ride is Turn rear track shock
harsh/stiff in both the front compression knob counter-
and rear of rear suspension clockwise one click at a time.
Turn rear track shock
Ride is harsh in stutter/
compression knob counter-
chatter bumps
clockwise one click at a time.
NOTE: Riders at the far ends of each rear track

springs rider weight/preload settings may want to
adjust the compression dampener base settings.
Lighter drivers should decrease the dampening by
one click, while heavier riders may want to increase
the dampening by one to two clicks.
Rear Track Shock Thrust Bearing

2011 and newer 600/800 Rush/Switchback models
feature rear track shock retainers with a thrust bearing.
The bearing significantly reduces the effort required to
adjust the rear track shock spring.

8.63
PROGRESSIVE REAR SUSPENSION 6. Remove the upper carrier wheel assembly from the
REMOVAL AND INSTALLATION rear crank.
Removal
1. Place a large mat, shop blanket, or piece of
cardboard on the floor next to the snowmobile. The
piece should be large enough to protect the plastics
when the unit is laid on its side.
2. Remove the rear bumper assembly from the rear
crank.
UPPER CARRIER
7. Remove the two fasteners and nuts securing the rear

pivot to the rear crank.
BUMPER FASTENERS
3. Loosen, but do not remove, the rear idler wheel

fasteners.
4. Loosen the track tension adjuster jam nuts. Back out
the threaded adjusters until flush with adjuster blocks.
PIVOT FASTENER
REAR
TRACKIDLER FASTENER
TENSION ADJ.
8. The rear of the suspension is now free to drop out of

the tunnel if required.
REAR IDLER FASTENER
5. Using a snowmobile lift, raise the vehicle high enough

off the ground to remove the vehicle weight from the
rear suspension.

9. Locate and remove the two fasteners and threaded 6. Fold the rear scissor forward, and then work the rear
pivot shafts securing the front torque arm to the of the skid into the track.
tunnel. 7. Once the suspension is installed in the track, work the
10. The suspension should now be hanging inside the track to align the sliders with the track clips and
track. guides.
11. Lower the snowmobile down to the floor. Remove the 8. Position the front torque arm and align its mounting
sled lift. holes with the holes in the tunnel. Loosely install the
12. Carefully role the snowmobile on to its side making front torque arm threaded pivots and fasteners.
sure the plastics are protected by the mat or blanket 9. Loosely install the rear pivot-to-rear crank carriage
previously placed on the ground. bolts and nuts. Verify the carriage bolts are fully
13. Fold the rear scissor forward. Remove the suspension seated into the rear crank.
from the track by working the rear free from the track, 10. Roll the snowmobile back on to its skis. Raise the
and then pulling the front torque arm out of the tunnel. snowmobile up off the ground using a snowmobile lift.
11. Torque the front torque arm mounting bolts to
specification.
12. Torque the rear pivot mounting nuts to specification.
13. Reinstall the upper carrier wheel assembly. Torque
fasteners to specification.
14. Reinstall the rear bumper assembly. Loosely install all
of the bumper fasteners first, and then torque to
specification.
15. Set the track tension to specification using the track
tension adjustment screws. Once the track tension is
set, torque the jam nuts to specification.
16. Torque the rear idler fasteners to specification.
Rear Crank Service

14. Roll the snowmobile back over on to the skis. 1. To remove the rear crank assembly, raise the
snowmobile off the ground using a snowmobile lift.
15. If the track removal is required, reference the
driveshaft removal procedure in chapter five. The 2. Remove the rear track shock spring tension by turning 8
track can be removed after the driveshaft is removed the preload adjuster counter-clockwise.
from the vehicle. 3. Remove the fasteners securing the upper carrier
16. The rear suspension bushings, shafts, and pivots assembly to the rear crank.
should be inspected. Replace bushings that are worn 4. Remove the fasteners securing the rear crank to the
or damaged. Replace any part that is worn rear pivot. Allow the suspension rail assembly to drop
excessively or damaged. to the ground.
5. Remove the rear track shock fastener from the rear
Installation crank.
6. Remove the two fasteners securing the rear crank to
1. If the track was removed, reinstall the track into the the tunnel mounts. Remove the screws attaching the
tunnel. Verify the arrow marks on the track point in reservoir to the rear crank.
the direction of forward vehicle travel.
7. Remove the rear crank assembly.
2. Reference the driveshaft installation procedure
outlined in chapter five. 8. Reverse procedure to assemble the rear crank.
Reference to torque specifications located on the
3. Place a protective mat, shop blanket, or large piece
assembly view illustrations.
of cardboard on the ground next to the vehicle.
4. Carefully roll the snowmobile on to its side making
sure the plastics are protected by the mat, blanket or
cardboard.
5. Install the rear suspension into the track by inserting
the front torque arm assembly into the tunnel at an
angle.

8.65
Rear Track Shock Service 8. Assembly is the reverse of removal. Torque fasteners
to specification using new lock nuts.
1. Raise the snowmobile off the ground with a
snowmobile lift.
NOTE: Lifting at the bumper will compress the RTS. =T
2. Remove the seat assembly.
Rear Track Shock Fasteners: 33 ft-lb (45 Nm)
3. Remove the nut holding the fuel tank to the x-brace. Reservoir Clamp Screws: 17 ft-lb (23 Nm)
Fuel Tank Screw: 7 ft-lb (10 Nm)
Seat Screws 7 ft-lb (10 Nm)
4. Remove the nut securing the shock to the rear crank.

5. Carefully lift up the rear of the fuel tank to access the
shock fasteners. Prop the tank with a block of wood.
6. Remove the shock. To remove spring, turn preload
knob counter-clockwise. Remove spring retainer, and
then spring.
7. To remove the reservoir, remove the two clamp
screws. Note the orientation of the reservoir hose.
route the hose as shown during installation.

RMK COIL-OVER REAR SUSPENSION All RMK coil-over rear suspensions are manufactured with
STANDARD rear track shock springs that will
Suspension Adjustments accommodate rider weights (with gear) up to
340 lbs. (154kg).
The primary tuning component on all RMK coil-over rear
suspensions is the rear track shock spring installed length. Initially, the rear track shock spring should be set to the
riders weight (with gear). Reference the Rear Track
Shock Spring (RTSS) Setup Table below.
RTSS Setup-Standard Spring

(Measure spring length with suspension off the ground.)
RIDER WEIGHT INSTALLED SPRING LENGTH
MODEL
(WITH GEAR) (REAR SUSPENSION OFF THE GROUND)
LBS. KG INCHES CM
RMK
10 3/4 27.3
<160 <73 PRO RMK 155/163
RMK ASSAULT 10 7/8 27.6
RMK 10 1/4 26
160-220 73-100 PRO RMK 155/163 10 3/8 26.3
RMK ASSAULT 10 1/4 26
RMK
10 1/8 25.7
220-280 100-127 PRO RMK 155/163
RMK ASSAULT 10 25.4
RMK
9 3/4 24.8
280-340 127-154 PRO RMK 155/163
RMK ASSAULT 9 1/2 24.1 8
NOTE: BOLD/SHADED CELLS = FACTORY SETTING.
CAUTION
CAUTION: Do not adjust STANDARD spring length

greater than (>) or less than (<):
RMK = >10 3/4" or <9 5/8"
PRO RMK = >11" or <9 3/4"
RMK Assault = >11" or <9 3/8"
RMK Coil-Over Standard Springs

RMK = 7043680-133 (210 Rate)
PRO RMK = 7043714-133 (190 Rate)
RMK Assault = 7043572-133 (210 Rate)

8.67
Heavy Duty Rear Track Shock Spring-RMK The part number for the HD spring is 7043741-067.
Coil-Over Reference the RTSS Setup-Heavy Duty Spring Table
below.
An optional HEAVY DUTY spring is available if
adjustments to the factory-installed springs are not
sufficient for riders over 300 lbs. (136kg).
RTSS Setup-Heavy Duty Spring

(Measure spring length with suspension off the ground.)
RIDER WEIGHT INSTALLED SPRING LENGTH
MODEL
(WITH GEAR) (REAR SUSPENSION OFF THE GROUND)
LBS. KG INCHES CM
250-300 113-136 RMK 10 1/8 25.7
PRO RMK 155/163
300-350 136-159 RMK ASSAULT 10 25.4
Spring Retainer Spanner Wrench

CAUTION
Use the spanner wrench included in the tool kit to adjust
the rear track shock spring installed length.
CAUTION: Do not adjust HEAVY DUTY spring length
greater than (>) or less than (<):
ALL MODELS = >10 7/8" or < 9 7/8"
Measuring Rear Track Shock Spring Installed

Length
1. Lift the rear of the snowmobile off the ground or tip
the snowmobile on to its side to remove the weight
from the rear suspension.
2. Use a tape measure to measure the spring installed
length between the two spring retainers. Spanner Wrench PN:
2871095-329
INSTALLED LENGTH
3. To adjust, clear away any snow/ice that may be

trapped within the spring or threads. Rotate the spring
using a spanner wrench to change the length.
Regardless of spring type, do not adjust the spring
past the MAXIMUM or MINIMUM measurements.

Fine Tuning Adjustments Shock Dampening
Additional minor adjustments can be made to the spring Compression damping adjustments can be made on 800
length to adjust the feel of the vehicle. Do not exceed the RMK and 800 RMK Assault models to control ride quality
minimum and maximum installed length requirements. and bottoming resistance.
For more ski lift (transfer), reduce spring preload by 600/800 RMK - Rear Track Shock
increasing the installed length. Rotate the spring 1-2 full
turns counter-clockwise (when viewed from bottom). This Make the adjustments in half-turn increments, then test
will enhance maneuverability, making the snowmobile ride. To stop bottoming, turn the damping screw clockwise
more flickable although it may hinder climbing one half-turn, then test ride. Repeat the adjustment until
performance. bottoming stops and the desired ride quality is achieved.
For less ski lift (transfer), increase spring preload by

reducing the installed length. Rotate the spring 1-2 full
COMPRESSION SCREW
turns clockwise (when viewed from bottom). This will
improve climbing ability and rider control.
To control the overall balance of the vehicle use the

following guidelines:
More rear track shock spring preload increases ski

pressure. Less preload decreases ski pressure.
Spring preload can affect bottoming resistance. 800 RMK Assault - IFS and Rear Track Shocks
More preload means less bottoming. Less preload
means a softer ride (and more bottoming). Compression damping can be adjusted at the front
suspension and at the rear track shock. Make adjustments
Both adjustments will affect overall balance and ski in 2-click increments, then test ride. When adjusting the
pressure. front suspension, always adjust both clickers equally.
After adjusting RTSS preload, the front track shock (FTS) To stop bottoming of the front or rear suspension (stiffer
spring preload and independent front suspension (IFS) ride), rotate the clicker(s) clockwise two clicks (as viewed
spring preload can also be adjusted. from the top of the clicker), then test ride. Repeat the 8
adjustment until bottoming stops and the desired ride
For a softer ride on rough, washboard surfaces, reduce
quality is achieved.
front track shock (FTS) spring preload by 1-2 turns.
For a more plush ride at the front or rear suspension, rotate
To improve corner stability, increase front suspension
the clicker(s) counterclockwise two clicks, then test ride.
(IFS) spring preload by 1-2 turns on both sides of the
Repeat the adjustment until the desired ride quality is
vehicle.
achieved.

8.69
RAIL SLIDERS
Wear Limit
Replace sliders when wear exceeds notch. If sliders look

wavy in appearance, check and adjust track tension or
consider adding more bogie wheels.
Removal/Installation
1. Raise the snowmobile off the ground using a
snowmobile lift.
2. Remove front rail slider retaining bolt, located at the
rail tip.
3. Use a block of wood or a drift punch and hammer to
drive the slider rearward off the slide rail.
4. With the rail slider at room temperature, install a new
rail slider by reversing steps 1 - 3.
NOTE: Lightly coat rail slider track clip area with a
lubricant such as LPS2 or WD-40 to ease installation.
Break-In
After installing new rail sliders they must be broken-in for
longer life and better wear patterns. When performing the
break-in procedure, ride the sled on a surface that has
adequate snow conditions with deeper snow nearby. Run
the sled on the adequate snow surface and dip into the
deeper snow every so often.

Chassis
CHAPTER 9
Chassis
SAFETY INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
GENERAL CAUTIONS AND NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
LORD 406 ACRYLIC ADHESIVE INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.2
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
FASTENER TORQUE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.3
CHASSIS ASSEMBLIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
HOOD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.4
LEFT/RIGHT DOORS AND FENDERS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.5
NOSEPAN-RUSH /SWITCHBACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
FRONT BUMPER- RUSH/SWITCHBACK. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.6
FRONT BUMPER/NOSEPAN-SWITCHBACK ASSAULT/RMK . . . . . . . . . . . . . . . . . . . 9.7
SEAT/SEAT SUPPORT-RUSH MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.8
SEAT/SEAT SUPPORT-SWITCHBACK MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.9
SEAT/SEAT SUPPORT-SWITCHBACK ADVENTURE . . . . . . . . . . . . . . . . . . . . . . . . 9.10
SEAT/SEAT SUPPORT-SWITCHBACK ASSAULT/RMK . . . . . . . . . . . . . . . . . . . . . . . 9.11
FRONT/REAR OVER STRUCTURE/X BRACE-RUSH MODELS. . . . . . . . . . . . . . . . . 9.12
FRONT/REAR OVER STRUCTURE/X BRACE-SWITCHBACK MODELS. . . . . . . . . . 9.13
FRONT/REAR OVER STRUCTURE-SWITCHBACK ASSAULT/RMK MODELS . . . . . 9.14
LEFT/RIGHT BULKHEAD CLIPS/SIDE BRACES-ALL MODELS . . . . . . . . . . . . . . . . . 9.15
TUNNEL REAR-RUSH MODELS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.16
TUNNEL REAR-SWITCHBACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.17
TUNNEL REAR-SWITCHBACK ASSAULT/RMK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.18
LEFT/RIGHT FOOT SUPPORTS-RUSH/SWITCHBACK MODELS . . . . . . . . . . . . . . . 9.19
SWITCHBACK ADVENTURE SADDLE BAGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.20
BONDED COMPONENT SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
BONDED COMPONENT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
BONDED COMPONENT SURFACE PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . 9.21
ADHESIVE APPLICATOR KITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
ADHESIVE APPLICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.22
ADHESIVE APPLICATION PATTERNS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.23
9
BULKHEAD FLOOR PLATE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
BULKHEAD FLOOR PLATE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
FRONT TUNNEL BULKHEAD COOLER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . 9.25
FRONT TUNNEL BULKHEAD COOLER INSTALLATION . . . . . . . . . . . . . . . . . . . . . . 9.26
LEFT BULKHEAD CLIP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.27
LEFT BULKHEAD CLIP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.29
RIGHT BULKHEAD CLIP REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.30
RIGHT BULKHEAD CLIP INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.33
LEFT SUPPORT BRACE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.35
LEFT SUPPORT BRACE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.36
RIGHT SUPPORT BRACE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.36
RIGHT SUPPORT BRACE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9.38

9.1
Chassis
SAFETY INFORMATION Lord 406 Acrylic Adhesive Information
General Cautions and Notes Review and understand the following product handling
practices and first aid measures prior to working with
Never re-use lock Nuts. Always replace lock nuts bonding adhesive.
that have been removed with new parts.
Never re-use pre-coated fasteners. Always For additional handling, first aid, or MSDS information,
replace pre-coated fasteners with new parts. contact Lord at www.lord.com.
The side braces, bulkhead floor, and the front
tunnel cooler upper mating surface are bonded WARNING
components.
The only authorized bonding adhesive is Lord 406 Lord 406 Acrylic Adhesive is flammable. Do not store or
Acrylic Adhesive. DO NOT ANY NON-SPECIFIED use near heat, sparks, or open flame.
BONDING ADHESIVE, GLUE, OR EPOXY.
Lord 406 Acrylic Adhesive has a shelf life of no Handling Practices
more than 60 days at 68 F (20 C) from the time Ventilation - Work in a well-ventilated area.
of manufacture. Do not store this product. Order
repair kit as required and dispose product after Respirator - Use properly-fitted, organic vapor, air
repair is completed in accordance with local rules purifying respirator (face mask).
and regulations.
Wear gloves, face mask, and protective eye wear Skin Protection - Use neoprene, or rubber gloves. Wash
when removing original adhesive from chassis hands and exposed skin with soap and water after
components. working with product.
Never apply excessive heat or flame to bonded
components when not intending to remove them Eye Protection - Wear safety glasses/goggles.
from the chassis.
The engine overstructure/steering support
assembly and floor board support tubes are First Aid Measures
bonded components. THESE COMPONENTS Eye Contact - Flush eyes immediately with large
ARE NOT SERVICEABLE. REPLACE AS amounts of water for at least 15 minutes holding eyelids
COMPLETE ASSEMBLIES. open while flushing. Get prompt medical attention.
Bonded components must be removed, cleaned,
and re-bonded if the adhesive is subjected to Skin Contact - Flush contaminated skin with large
temperatures above 300 F (149 C). amounts of water while removing contaminated
Adhesive working time is 6 to 10 minutes. clothing. Wash affected skin areas with soap and water.
Component handling time is achieved within 60 Get medical attention if symptoms occur.
minutes. Complete cure time will take 24 hours at
68 F (20 C). Inhalation - Move person to fresh air. Restore and
Allow the adhesive to cure at room temperature support continued breathing. If breathing is difficult, give
68 F (20 C). Do not move the snowmobile oxygen. Get immediate medical attention.
outside (colder temperature) while the adhesive is
curing. Ingestion - If swallowed, do not induce vomiting. Give
Do not place the vehicle into service until the victim one or two glasses of water or milk. Call a
adhesive has completely cured (24 hours). physician or poison control center immediately for
further instructions. Never give anything by mouth if
victim is rapidly losing consciousness, unconscious, or
convulsing.

Chassis
SPECIFICATIONS COMPONENT TORQUE
Fastener Torque Specifications Front footrest tube/rear

22 ft-lb (30 Nm)
over structure fasteners
COMPONENT TORQUE Running board support-to-
26 ft-lb (35 Nm)
rear support braces
Rear hood-to-rear over
7.4 ft-lb (10 Nm) Rear support brace tunnel
structure screws 26 ft-lb (35 Nm)
fasteners
Head light asm.front/air box
3 ft-lb (4 Nm) Bulkhead cooler-to-tunnel/
screws 26 ft-lb (35 Nm)
braces fasteners
Head light asm. side
7.4 ft-lb (10 Nm)
mounting screws
Front bumper-to-over
structure/heat exchanger 7.4 ft-lb (10 Nm)
fasteners
Seat screws 7.4 ft-lb (10 Nm)
Seat brace-to-x brace
7.4 ft-lb (10 Nm)
screws
Seat brace-to-rear brace
17 ft-lb (23 Nm)
screws
Bulkhead clip fasteners/
26 ft-lb (35 Nm)
nuts
Exhaust silencer fasteners/
26 ft-lb (35 Nm)
nuts
Right side brace fasteners/
26 ft-lb (35 Nm)
nuts
Left side brace fasteners/
26 ft-lb (35 Nm)
nuts
Left side front/rear engine
22 ft-lb (30 Nm)
9
mounts-brace fasteners
Cross brace screws 35 ft-lb (47 Nm)
Front over structure-to-
22 ft-lb (30 Nm)
bulkhead clip fasteners
Front over structure-to-rear
over structure tube 17 ft-lb (23 Nm)
fasteners
Rope guide fastener 7 ft-lb (9.5 Nm)
Rear over structure-to-front
tunnel mount/x-brace 35 ft-lb (47 Nm)
fastener
Rear over structure-to-
22 ft-lb (30 Nm)
tunnel fastener
X-brace-to-rear brace
35 ft-lb (47 Nm)
support fasteners

9.3
Chassis
CHASSIS ASSEMBLIES
Hood
INSTRUMENT CLUSTER
GASKET
A
2012 BRAKE DUCT IGNITION SWITCH
B
A
MESH SCREEN
FILTER
2010-2011 BRAKE DUCT
FILTER BRACKET
B AIRBOX
B
SCREENS
Front
BELT/BELT HOLDER
=T
A: 7.4 ft-lb (10 Nm)
B: 3 ft-lb (4 Nm) (Airbox/Headlight Asm. Screws)
If the brake duct mounting posts break on a 2010-2011

Rush or Switchback Assault hood, install the Brake Duct
Kit, PN 2204584.

Chassis
Left/Right Doors and Fenders
1/4 TURN STUD
SIDE PANEL SCREEN 1/4 TURN RETAINER
RIGHT DOOR
1/4 TURN STUD

1/4 TURN CLIP
RIGHT FENDER
SIDE PANEL SCREEN

1/4 TURN CLIP
RH LEFT DOOR
EXHAUST SEAL
SNOW DEFLECTOR
1/4 TURN CLIP
Front LH
RUBBER STRAP
1/4 TURN CLIP

9
LEFT FENDER

9.5
Chassis
Nosepan-Rush /Switchback
NOSEPAN
AIR DAM PLATE
Front Bumper- Rush/Switchback
A
HEAT EXCHANGER BRACKET
FRONT BUMPER
=T
A: 7.4 ft-lb (10 Nm)

Chassis
Front Bumper/Nosepan-Switchback
Assualt/RMK
BUMPER PLUG
FRONT BUMPER
LOWER FRONT BUMPER
FIBER PAD
9
NOSEPAN
=T
A: 7.4 ft-lb (10 Nm)

9.7
Chassis
Seat/Seat Support-Rush Models
B
SEAT SEAT SUPPORT
B
A
B
A
X BRACE
A
LE SUPPORT
=T
A: 7.4 ft-lb (10 Nm)
B: 17 ft-lb (23 Nm)

Chassis
Seat/Seat Support-Switchback Models
SEAT
A
B
SEAT SUPPORT
B
A
=T
A: 7.4 ft-lb (10 Nm)
B: 17 ft-lb (23 Nm) 9

9.9
Chassis
Seat/Seat Support-Switchback Adventure
RACK LINER
B A SEAT SUPPORT
SEAT
A
A
=T
A: 7.4 ft-lb (10 Nm)
B: 17 ft-lb (23 Nm)

Chassis
Seat/Seat Support-Switchback Assault/RMK
SEAT
SEAT SUPPORT
A
A
WASHERS
=T
A: 7.4 ft-lb (10 Nm)

9.11
Chassis
Front/Rear Over Structure/X Brace-Rush Models
ROPE GUIDE X BRACE

REAR OVER STRUCTURE
C
TUBE SPACER
D
D
D
A
FRONT OVER STRUCTURE
D
A
D
A
FOAM PADS
D
D
2011-CURRENT MODELS = HEX SCREWS
=T
A: 35 ft-lb (47 Nm)
B: 17 ft-lb (23 Nm)
C: 7 ft-lb (9.5 Nm)
D: 22 ft-lb (30 Nm)
CAUTION
Front and rear over structure assemblies feature bonded

components. Do not attempt to service over structure
tubes.

Chassis
Front/Rear Over Structure/X Brace-Switchback Models
ROPE GUIDE REAR OVER STRUCTURE
X BRACE
C
TUBE SPACER
D
D
D
A
FRONT OVER STRUCTURE D
A
D
FOAM PADS A
D
D
9
2011-CURRENT MODELS = HEX SCREWS
=T
A: 35 ft-lb (47 Nm)
B: 17 ft-lb (23 Nm)
C: 7 ft-lb (9.5 Nm)
D: 22 ft-lb (30 Nm)
CAUTION

tubes.

9.13
Chassis
Front/Rear Over Structure-Switchback
Assault/RMK Models
FOOT REST
CLUTCH GUARD
REAR OVER STRUCTURE FOOT REST

TUBE SPACER
B STUD PLATE
TPS GUARD
B WASHERS
STUD PLATE
A
B A
B
B B
FRONT OVER STRUCTURE
RUNNING BOARD SUPPORT
=T
A: 7 ft-lb (9.5 Nm)
B: 22 ft-lb (30 Nm)
CAUTION

tubes.

Chassis
Left/Right Bulkhead Clips/Side Braces-All Models
EXHAUST SILENCER BRACKET (DC-CFI-2 MODELS ONLY)
C
EXHAUST SILENCER BRACKET
C RIGHT SIDE PLATE*
C
C C
C
A C
C
BULKHEAD FLOOR PLATE*
CROSS BRACE
C C
RIGHT BULKHEAD CLIP* REAR PTO ENGINE MOUNT
A-ARM STUDS
A
C
C
FRONT PTO ENGINE MOUNT
C
C B (PLATE/ENGINE MOUNT SCREWS)
LEFT SIDE PLATE*
C
9
LEFT BULKHEAD CLIP* C B (PLATE/ENGINE MOUNT SCREWS)
=T
A: 35 ft-lb (47 Nm)
B: 22 ft-lb (30 Nm)
C: 26 ft-lb (35 Nm)
NOTE: * = Bonded component.

9.15
Chassis
Tunnel Rear-Rush Models
RUNNING BOARD SUPPORT RUNNING BOARD CLOSEOFF
A REAR SUPPORT BRACES
TUNNEL GRIPPER RUNNING BOARD CLOSEOFF

A
A
A
TUNNEL GRIPPER
=T
A: 26 ft-lb (35 Nm)
CAUTION
Running board supports feature bonded components.

Do not attempt to service supports.

Chassis
Tunnel Rear-Switchback
RUNNING BOARD SUPPORT RUNNING BOARD CLOSEOFF REAR SUPPORT BRACES

A
A RUNNING BOARD CLOSEOFF

TUNNEL GRIPPER
A A
TUNNEL GRIPPER
=T
A: 26 ft-lb (35 Nm)
9
CAUTION


9.17
Chassis
Tunnel Rear-Switchback Assault/RMK
BUMPER SUPPORT
BRAKE LIGHT COVER BUMPER TUBE

A
PLUG
BRAKE LIGHT WIRE CHANNEL
SNOW FLAP
CLOSEOFF
=T
A: 7 ft-lb (9.5 Nm)

Chassis
Left/Right Foot Supports-Rush/Switchback
Models
RH UPPER FOOTREST
FOOTREST TUBE
RH
REAR OVER STRUCTURE
RH LOWER FOOTREST
A
LH UPPER FOOTREST
FOOTREST TUBE
A
Front
CLUTCH GUARD
B
LH LOWER FOOTREST
TPS GUARD
LH
After removing the rear over structure, the rivets securing

=T the upper footrest panels to the tubes can be drilled out.
9
A: 22 ft-lb (30 Nm)
B: 7.4 ft-lb (10 Nm)
Assembly Notes:
To remove the rear over structure from the tunnel after all
of the fasteners are removed, the rivets attaching the
lower footrests to the footrest tubes have to be removed
along with the rivets attaching the footrest tubes to the RIVETS
tunnel grippers.
RIVETS
RIGHT SIDE ASSEMBLY SHOWN

9.19
Chassis
Switchback Adventure Saddle Bags
SADDLE BAG LID RUBBER STRAPS
LOCK N RIDE ANCHOR
LOCK N RIDE ANCHOR
RETAINER CABLE
SADDLE BAG
LID HINGE
BAG SUPPORT BRACKET
LOCK N RIDE ANCHOR
=T
Retainer Cable Fasteners: 3 ft-lb (4 Nm)
Lid Hinge Fasteners: 7.3 ft-lb (10 Nm)
CAUTION


Chassis
BONDED COMPONENT SERVICE Bonded Component Surface Preparation
Overview
WARNING
The following serviceable components are bonded with
structural adhesive: Handling Practices
Ventilation - Work in a well-ventilated area.
Left/right bulkhead clips are bonded to the left/right
support braces Respirator - Use properly-fitted, organic vapor, air
Left/right support braces are bonded to the tunnel purifying respirator (face mask).
assembly
Bulkhead floor plate Skin Protection - Use neoprene, or rubber gloves. Wash
Top of front tunnel bulkhead cooler hands and exposed skin with soap and water after
NOTE: The left and right bulkhead clips are not working with product.
bonded to each other.
Eye Protection - Wear safety glasses/goggles.
Please read and understand the topics outlined on the
following pages before working with any bonded
component. CAUTION
Bonded Component Removal Original adhesive must be removed from bonded

components prior to the application of new adhesive.
Breaking the adhesive bond between the before-
mentioned components is required whenever performing Bonded components that will be re-used during assembly
the following repairs: must be cleaned and free from original adhesive.
Left or right bulkhead clip removal/replacement
Remove adhesive using a putty knife, gasket remover
Left or right engine support side brace removal/
tool, wire brush, etc. and propane gas torch.
replacement
Front tunnel cooler removal/replacement
Apply heat to adhesive to assist in removal. After all of the
residual adhesive is removed, the component mating
In every repair procedure listed, the bulkhead floor plate
surface should resemble the example in the photo below.
must be removed. Breaking the bulkhead floor plate bond
will render the part unusable. The bulkhead floor plate is
considered a sacrificial part and will always be replaced
with a new plate whenever removed.
There are two removal methods. The first method does not
9
require the use of the direct application of heat to break the
bond. This method only involves removing the bulkhead
floor plate and front tunnel bulkhead cooler. This method
works because the adhesive has very little resistance to
peel force and therefore the two parts can be easily pried/
peeled off of the chassis.
The second removal method requires the use of the direct

application of heat to release the bond. This method of
removal only involves the removal of the bulkhead clip(s)
and/or engine support brace(s).
After removing the adhesive, clean the bonding area with
The recommended source of heat is the use of propane warm, soapy water and allow to dry completely.
gas, and can be obtained at most commercial hardware NOTE: New bonded parts should be washed with
stores. warm, soapy water and allowed to dry completely
NOTE: In all bonded component repair procedures, before the adhesive is applied.
the engine assembly and bulkhead floor plate are
removed from the engine compartment.

9.21
Chassis
Adhesive Applicator Kits Obtaining Adhesive/Mixing Tools Commercially
The only Polaris-authorized adhesive is Lord 406/
Polaris offers a repair kit, individual adhesive cartridges, 19 Acrylic Adhesive (Lord 50mL PN:3003680).
and replacement needle packs. The adhesive has a shelf Do not use Lord Fusor Adhesive.
life of sixty days from the date of manufacture when stored Lord Dispensing Gun = Lord Pak 50 (3001112)
at room temperature (68 F/20 C). Lord Plunger = Lord Pak 50 4:1 Plunger
NOTE: Optimum storage temperature is 40-50 F (3004479)
(4-10 C). Lord Mixing Needles = .25"x6" Needle (3004476)
Leave mixer needle attached to cartridge when not in use. Adhesive Application
Discard the adhesive cartridge on the date of expiration NOTE: Read and understand the following steps to
noted on cartridge label in accordance with local rules and ensure the adhesive is applied correctly.
ordinances.
The adhesive has a maximum working time of 6 to 10
Lord 406/19 Repair Kit (50 mL): 2204171 minutes at room temperature. It is critical to pre-position all
Includes: of the components, screws, nuts, and tools before
-12qty. Static mixer needles applying any adhesive.
- 1qty. 50mL 406/19 adhesive cartridge
- 1qty. Standard caulking gun adapter sleeve All bonded components and mating surfaces must be
- 1qty. Plunger adapter
cleaned and free from grease, oils, dirt, etc. Clean all
Lord 406/19 50mL Adhesive Cartridge: 2204400 mating surfaces with a soap/water solution and allow to air
dry.
Lord Static Mixer Needles (12qty.): 2204172
Verify the adhesive and components are at room
temperature (68 F/20 C).
NOTE: The components, and adhesive, must be at
room temperature 68 F (20 C) to ensure the
adhesive cures properly.
1. When ready to apply the adhesive, remove the

cartridge end caps. Level the plunger by slowing
squeezing the trigger and expelling the adhesive
from the plug onto scrap piece of material.
REPAIR KIT: 2204171
The Lord 406/19 Repair Kit (2204171) is supplied with a

adapter sleeve and plunger adapter designed to work with
a standard size, caulk gun. A smooth rod-type caulk gun
is preferable over a ratchet rod type.
Perform the following steps to assemble the repair kit:

1. Insert the cartridge into the adapter sleeve.
2. Install the plunger into the back of the cartridge.
3. Install the plunger/cartridge into the caulk gun.
Manually extend the rod so it engages the plunger 2. Attach a new mixer needle to the cartridge.
squarely.
4. Squeeze the trigger slowly making sure the plunger
makes equal contact with both cartridge chambers.
5. Only install the mixer needle when ready to apply the
adhesive to the components.

Chassis
3. While holding the mixer needle over a piece of scrap Adhesive Application Patterns
material, slowly compress the caulk gun trigger to fill
the mixer needle. The needle will automatically mix Reference the following illustrations showing the exact
and dispense the correct volumetric ratio of adhesive patterns for each bonded component when applying the
and accelerator. adhesive.
BULKHEAD FLOOR
ADHESIVE
LINE
FRONT
4. Continue squeezing the trigger until a needles length

of adhesive is expelled.
LH (PTO) SIDE BRACE
5. Quickly apply a 4mm bead of adhesive to the
(BULKHEAD MATING SURFACE)
component as shown on the following pages. Apply
ADHESIVE
adhesive to one component at a time.
LINE
6. Carefully install the component and torque the
fasteners to specification immediately. Do not break
the bond once the components are mated.
CAUTION
The bonded parts can be repositioned by gently sliding APPLY ADHESIVE TO COOLER/PLATE MATING SURFACE
them into position. Never pull the parts apart. Doing so
will introduce air gaps and will require removing the
parts, and removing all adhesive. (FRONT CLIP MATING SURFACE)
ADHESIVE
7. When not using the adhesive, leave the mixer needle
9
LINE
attached to the cartridge.
8. If the needle has sat idle for any amount of time,
simply remove the needle, and repeat steps 2 though
4 to apply adhesive to additional components.
CAUTION
APPLY SMALL AMOUNT OF ADHESIVE HERE
Do not manually mix the adhesive and accelerator.
Always use a mixing needle to apply the adhesive.

9.23
Chassis
RH (MAG) SIDE BRACE Chaincase (2012 Models)
(MATING SURFACE)
(BULKHEAD MATING SURFACE)
ADHESIVE
LINE
ADHESIVE
LINE
APPLY ADHESIVE TO COOLER/PLATE MATING SURFACE
(FRONT CLIP MATING SURFACE)

ADHESIVE
LINE
ADHESIVE
APPLY SMALL AMOUNT OF ADHESIVE HERE
LINE
NOTE: Adhesive application can be used on 2010-

2011 models.
FRONT BULKHEAD COOLER/PLATE
(TUNNEL MATING SURFACE)
ADHESIVE
LINE

Chassis
Bulkhead Floor Plate Removal NOTE: Allow the adhesive to cure for 24 hours at 68
F (20 C) before placing the snowmobile back into
1. Follow the procedures for removing the engine. See service.
Engine chapter.
2. Remove the fender from the chassis on the side of the Front Tunnel Bulkhead Cooler Removal
vehicle that requires service.
3. The bulkhead floor plate is riveted and bonded to the 1. Remove the following components:
chassis.
Right/left engine compartment door
4. Locate and drill-out the rivets securing the plate to the
Hood
bulkhead clips, support plates and bulkhead cooler.
Exhaust pipe/silencer
Drill out the rivet in the center of the plate that secures
Oil tank/clutch cover assembly
the cooling hose p-clamp.
Airbox assembly
Engine assembly
Driven clutch
Bulkhead floor plate
Fuel tank assembly
2. Drill out the rivets securing the cooler to the top of the
tunnel.
3. Remove the fasteners securing the cooler to the sides
FLOOR PLATE
of the tunnel.
4. Remove the fasteners securing the engine support
braces to the cooler.
RIVETS 5. Remove the cooler from the chassis.
5. Insert the blade of a flat blade screwdriver into one of

the plates corners. Pry the plate away from the
chassis.
6. Continue working the screwdriver along the edge of
the plate until the plate can be grasped with a Vise
Grip pliers.
7. Using the Vise Grip pliers, pull/peel the plate away
from the chassis. Discard the plate.
8. Thoroughly clean the chassis mating surfaces where
the plate attaches to the chassis. Reference the
Bonded Component Surface Preparation section.
9
Bulkhead Floor Plate Installation
1. Clean the new bulkhead floor plate with warm, soapy
water. Allow the plate to completely dry.
2. The next assembly step is applying the adhesive.
Thoroughly read and understand the Adhesive
Applicator Tool and Adhesive Application sections
before proceeding.
3. Apply the adhesive to the plate. Reference the
illustration in the Adhesive Application Patterns
section.
4. Install the plate using new rivets.
5. Reinstall the fender.
6. Install the rivet securing the cooling hose p-clamp to
the plate from inside engine compartment.
7. Reinstall the engine assembly.

9.25
Chassis
6. Remove any residual adhesive from the tunnel and/ 8. Reinstall the following components:
or cooler if it is going to be re-used.
Front Tunnel Bulkhead Cooler Installation Hood
1. If installing the original bulkhead cooler, verify all of Oil tank/clutch cover assembly
the original adhesive is removed from the mating Airbox assembly
surface. Engine assembly
2. The next assembly step is applying the adhesive. Driven clutch
Thoroughly read and understand the Adhesive Bulkhead floor plate
Applicator Tool and Adhesive Application sections Fuel tank assembly
before proceeding. NOTE: Allow the adhesive to cure for 24 hours at 68
3. Apply the adhesive to the bulkhead cooler. Reference F (20 C) before placing the snowmobile back into
the illustration in the Adhesive Application Patterns service.
section.
4. Install the cooler using new rivets.
5. Install the fasteners securing the cooler to the engine
support braces. Torque to specification.
=T
Bulkhead Cooler-to-Tunnel/Braces:
26 ft-lb (35 Nm)
6. Install the fasteners securing the cooler to the sides

of the tunnel. Torque fasteners to specification.
=T
Bulkhead Cooler-to-Tunnel Fasteners:
26 ft-lb (35 Nm)
7. If the MAG rear engine mount bracket was removed

for the cooler, reinstall the mount and torque fasteners
to specification.
=T
MAG Engine Mount-to-Cooler Fasteners:
22 ft-lb (30 Nm)

Chassis
Left Bulkhead Clip Removal

Hood
Nosepan/bumper
Airbox assembly
Engine assembly
Left-side front engine mount
Left side front suspension components
Lower steering arm
Fuel tank (Remove fuel hoses and gasoline from
tank)
2. Drill out the rivets securing the left fender to the
bulkhead and chassis.
3. Remove the five fasteners and nuts (including the two
5. Remove the cross shaft fastener from the bulk head
engine mount fasteners/nuts) securing the bulkhead
clip.
clip to the left side engine side support brace.
4. Remove the bulkhead clip fasteners/nuts.

9
LOWER HEAT EXCHANGER MOUNT

9.27
Chassis
6. Remove the screws securing the over structure to the 9. Wearing heat resistant gloves, use a propane gas
bulk head clip. torch to heat the adhesive between the two
components.
Apply torch until adhesive begins to crackle. During
this time, the adhesive may smoke and bubble.
Continue heating the area until the components can
be separated.
7. Remove the tie rod boot. Remove the lower steering

shaft nut.
PROPANE GAS TORCH
CAUTION
Keep flame away from flammable materials. Use torch

in well-ventilated area.

where bond line separation is not needed. Doing so will
10. Once the adhesive bond is broken, remove the left-

8. When all of the noted fasteners and nuts are removed, side bulkhead clip from the chassis. Note the old
the next step is to heat where the bulkhead clip mates (residual) adhesive. If the component is to be re-used,
with the engine side support brace. the adhesive must be completely removed. See
OLD ADHESIVE

Chassis
Left Bulkhead Clip Installation 7. Reinstall the bulkhead clip fasteners including lower
heat exchanger mount screw/nut. Torque nuts to
1. Verify the bulkhead clip and engine side support specification.
brace are thoroughly cleaned and all residual
adhesive is removed from both parts.
2. Gather together the three T40 fasteners and nuts, and =T
two T40 engine mount screws that secure the
bulkhead clip to the engine side support brace. Bulkhead Clip Fasteners:
26 ft-lb (35 Nm)
Thoroughly read and understand the Adhesive 8. Reinstall the over structure-to-bulkhead screws.
Applicator Tool and Adhesive Application sections Torque screws to specification.
before proceeding.
4. Apply the adhesive to the front, left engine side
support brace as outlined in the Adhesive Application =T
section.
Over Structure-to-Bulkhead Fasteners:
5. Install the bulkhead clip. Install and torque the T40
22 ft-lb (30 Nm)
screws that attach the clip to the side support brace.
6. Torque fasteners to specification. 9. Reinstall the cross shaft fastener. Torque to
specification.
=T
9
Cross Shaft Fasteners: 35 ft-lb (47 Nm)
CAUTION
The fasteners must be torqued within the adhesive

working time of 6 to 10 minutes.
=T
Bulkhead Clip-to-Side Brace Fasteners:
26 ft-lb (35 Nm)
Engine Mount Fasteners: 22 ft-lb(30 Nm)

9.29
Chassis
10. Reinstall the lower steering shaft nut. Torque nut to Right Bulkhead Clip Removal
specification.

Hood

Nosepan/bumper


Exhaust silencer bracket


Airbox assembly

Engine assembly


Right side front suspension components

tank)
2. Drill out the rivets securing the right fender to the
3. Remove the exhaust silencer bracket.
=T
Steering Shaft Nut: 22 ft-lb (30 Nm)
11. Reinstall the tie rod boot.

12. Reinstall the bulkhead floor plate.
13. Reinstall the left fender assembly using new rivets.
14. Reinstall the following components:

Hood
Exhaust pipe/silencer Y
X

Z
Airbox assembly 4. Remove the two remaining brace screws and nuts.
Engine assembly
Left side front suspension components
NOTE: Allow the adhesive to cure for 24 hours at 68
service.

Chassis
5. Remove the bulkhead clip fasteners/nuts. 6. Remove the cross shaft fastener from the bulk head
clip.
LOWER HEAT EXCHANGER MOUNT

7. Remove the screws securing the over structure to the
bulk head clip.

9.31
Chassis
8. Remove the tie rod boot. Remove the idler arm bolt NOTE: Left side shown.
and nut.
PROPANE GAS TORCH
9. When all of the noted fasteners and nuts are removed, CAUTION
the next step is to heat where the bulkhead clip mates
with the engine side support brace.
10. Wearing heat resistant gloves, use a propane gas in well-ventilated area.
torch to heat the adhesive between the two
components. Only apply heat to area that requires adhesive bond
Apply torch until adhesive begins to crackle. During separation. Do not apply heat to areas of adhesive
this time, the adhesive may smoke and bubble. where bond line separation is not needed. Doing so will
Continue heating the area until the components can require removing the part, removing adhesive, and then
be separated. re-applying new adhesive.

Chassis
11. Once the adhesive bond is broken, remove the right- 6. Torque fasteners to specification.
side bulkhead clip from the chassis. Note the old
(residual) adhesive. If the component is to be re-used,
the adhesive must be completely removed. See
Y
X
Z
CAUTION

=T
Bulkhead Clip-to-Side Brace Fasteners:
Right Bulkhead Clip Installation Exhaust Bracket Fasteners
26 ft-lb (35 Nm)
1. Verify the bulkhead clip and engine side support
brace are thoroughly cleaned and all residual 7. Reinstall the bulkhead clip fasteners including lower
adhesive is removed from both parts. heat exchanger mount screw/nut. Torque nuts to
2. Gather together the two T40 fasteners and nuts, and specification.
the exhaust bracket screw and nuts that secure the
bulkhead clip to the side brace.
=T
Applicator Tool and Adhesive Application sections Bulkhead Clip Fasteners:
before proceeding.
4. Apply the adhesive to the front, right side brace as
26 ft-lb (35 Nm)
9
8. Reinstall the over structure-to-bulkhead screws.
outlined in the Adhesive Application section.
5. Install the bulkhead clip. Install and torque the T40
screws that attach the clip to the side support brace,
and the screw and three nuts that attach the exhaust
silencer bracket to the brace.

9.33
Chassis
Torque screws to specification. 10. Reinstall the idler arm bolt and nut. Torque nut to
specification.
=T
Idler Arm Nut: 37 ft-lb (50 Nm)
=T
11. Reinstall the tie rod boot.
Over Structure-to-Bulkhead Fasteners: 12. Reinstall the bulkhead floor plate.
22 ft-lb (30 Nm) 13. Reinstall the right fender assembly using new rivets.
14. Reinstall the following components:
9. Reinstall the cross shaft fastener. Torque to
specification. Right/left engine compartment door
Hood
Airbox assembly
Engine assembly
service.
=T
Cross Shaft Fasteners: 35 ft-lb (47 Nm)

Chassis
Left Support Brace Removal 5. Wearing heat resistant gloves, use a propane gas
torch to heat the where the brace mounts to the tunnel
1. Remove the following components: and bulkhead clip.
Right/left engine compartment door this time, the adhesive may smoke and bubble.
Hood Continue heating the area until the brace can be
Exhaust pipe/silencer separated from the bulkhead and tunnel.
Driven clutch
Airbox assembly
Engine assembly
Left-side front/rear engine mount
tank)
2. Drill out the rivets securing the left fender to the
3. Remove the three screws and nuts and seven screws
securing the bulkhead clip to the left side engine side
support brace.
Note the screw located on the inside of the brace PROPANE GAS TORCH
attaching the brace to the bulkhead cooler.
CAUTION


4. When all of the noted fasteners, nuts, and screws are

6. Note the residual adhesive on the brace, bulkhead clip
and tunnel. If the component is to be re-used, the 9
adhesive must be completely removed. See Bonded
removed, the next step is to heat where the brace
Component Surface Preparation section.
mounts to the tunnel and bulkhead clip.
OLD ADHESIVE

9.35
Chassis
Left Support Brace Installation NOTE: Allow the adhesive to cure for 24 hours at 68
1. Verify the bulkhead clip, side brace, and tunnel are service.
thoroughly cleaned and all residual adhesive is
removed from the parts.
2. Gather together the T40 screws and nuts, and engine
Right Support Brace Removal
mounts. 1. Remove the following components:
Applicator Tool and Adhesive Application sections Hood
before proceeding.
Nosepan/bumper
4. Apply the adhesive to the front and rear of the left side
brace as outlined in the Adhesive Application section.
Exhaust silencer bracket

Chaincase components/chaincase
5. Install the brace. Torque fasteners to specification.

Note the screw on the inside of the brace mounting the

Airbox assembly
brace to the bulkhead cooler.

Engine assembly



Fuel tank (remove fuel hoses and gasoline from
tank)
2. Drill out the rivets securing the right fender to the
3. Disassemble the chaincase. Remove the chaincase
from the tunnel and brace.
NOTE: 2012 models feature bonded chaincases.
THIS END INSIDE BULKHEAD
CAUTION

=T
Bulkhead Clip-to-Brace Fasteners: 26 ft-lb (35 Nm)
Brace-to-Tunnel Fasteners: 26 ft-lb (35 Nm) 4. Remove the exhaust silencer bracket.
Brace Engine Mount Fasteners: 22 ft-lb(30 Nm)
6. Install a new bulkhead floor plate.

7. Reinstall the left side fender using new rivets.
8. Install the following components:

Hood
Driven clutch
Airbox assembly
Engine assembly Y
X
Z

Chassis
5. Remove the four remaining brace screws and nuts. 8. Note the residual adhesive on the brace, bulkhead clip
Note the screw located on the inside of the brace and tunnel. If the component is to be re-used, the
attaching the brace to the bulkhead cooler. adhesive must be completely removed. See Bonded
Component Surface Preparation section.
6. When all of the noted fasteners, nuts, and screws are

removed, the next step is to heat where the brace
mounts to the tunnel and bulkhead clip.
OLD ADHESIVE
7. Wearing heat resistant gloves, use a propane gas
torch to heat the where the brace mounts to the tunnel
and bulkhead clip.
this time, the adhesive may smoke and bubble.
Continue heating the area until the brace can be
separated from the bulkhead and tunnel.
NOTE: Left side shown.
9
PROPANE GAS TORCH
CAUTION



9.37
Chassis
Right Support Brace Installation
=T
1. Verify the bulkhead clip, side brace, and tunnel are
thoroughly cleaned and all residual adhesive is Bulkhead Clip-to-Brace Fasteners: 26 ft-lb (35 Nm)
removed from the parts. Brace-to-Tunnel Fasteners: 26 ft-lb (35 Nm)
2. Gather together the T40 screws and nuts, and Exhaust Bracket Fasteners: 26 ft-lb (35 Nm)
exhaust silencer bracket and nuts.
3. The next assembly step is applying the adhesive. 6. Install a new bulkhead floor plate.
Thoroughly read and understand the Adhesive 7. Reinstall the right side fender using new rivets.
Applicator Tool and Adhesive Application sections 8. Reinstall the following components:
before proceeding.
4. Apply the adhesive to the front and rear of the right Right/left engine compartment door
side brace as outlined in the Adhesive Application Hood
section. Nosepan/bumper
5. Install the brace. Torque fasteners to specification. Exhaust pipe/silencer
Note the screw on the inside of the brace mounting the Exhaust silencer bracket
brace to the bulkhead cooler. Chaincase components/chaincase
Airbox assembly
Engine assembly
service.
THIS END INSIDE BULKHEAD
Y
X
Z
CAUTION


Battery and Electrical Systems
CHAPTER 10
Battery and Electrical
SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
ENGINE MODELS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
SPARK PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
CHARGING/LIGHTING SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.3
INSTRUMENT CLUSTER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.4
RIDER INFORMATION DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
INSTRUMENT CLUSTER PINOUTS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
ENGINE RPM/VEHICLE SPEED DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.5
PERFORMANCE INFORMATION AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
VEHICLE INFORMATION AREA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
CHANGING UNITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
DIAGNOSTIC DISPLAY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
PLAYBACK MODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.6
SECURITY SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
SECURITY SYSTEM: OVERVIEW . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.7
SECURITY SYSTEM: DIGITAL WRENCH ENABLE. . . . . . . . . . . . . . . . . . . . . . . . . 10.7
SECURITY SYSTEM: DIGITAL WRENCH DISABLE . . . . . . . . . . . . . . . . . . . . . . . . 10.9
SECURITY SYSTEM: DIGITAL WRENCH PASSCODE RESET . . . . . . . . . . . . . . 10.10
SECURITY SYSTEM: INSTRUMENT CLUSTER INITIALIZATION . . . . . . . . . . . . . . 10.11
SECURITY SYSTEM: LOCKING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.13
SECURITY SYSTEM: UNLOCKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.14
SECURITY SYSTEM: CHANGING PASSCODE . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
SECURITY SYSTEM: USER NOTES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.15
MAINTENANCE-FREE BATTERY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
SPECIFICATIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
BATTERY REMOVAL/INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
BATTERY PREPARATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.16
CHARGING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
BATTERY TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
OCV - OPEN CIRCUIT VOLTAGE TEST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
LOAD TEST. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.17
BATTERY CONDUCTANCE ANALYZER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
BATTERY OFF SEASON STORAGE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.18
ELECTRIC START. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
SYSTEM SCHEMATIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.19
10
STARTER MOTOR/FLEX DRIVE ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
STARTER MOTOR/FLEX DRIVE SERVICE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.20
BATTERY BOX ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.21
IGNITION TIMING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
TIMING PROCEDURE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.22
IGNITION TIMING CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.23

10.1
DC-CFI ELECTRICAL SYSTEMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
DC-CFI STATOR ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.24
DC REGULATOR/RECTIFIER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
DC-CFI CHASSIS POWER CAPACITOR . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.25
DC-CFI AC REGULATOR/BATTERY CHARGE RECTIFIER . . . . . . . . . . . . . . . . . . . 10.25
IGNITION COIL PACKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
EXHAUST VALVE SOLENOID. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
OIL LEVEL SENDER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
LH CONTROL ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.26
DC-CFI REGULATED (RED) POWER CIRCUITS . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.27
DC-CFI CHASSIS (RED/WHITE) POWER CIRCUITS. . . . . . . . . . . . . . . . . . . . . . . . . 10.28
DC-CFI AC POWER (LIGHTING) CIRCUITS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.29
DC-CFI THROTTLE/IGNITION KILL SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.30
DIAGNOSTIC PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
POWER TEST PLUGS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
DC PWR PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
ECM PWR PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
FUEL PUMP PRIME PLUG . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
AC PWR PLUG. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.31
HAND/THUMB WARMERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
THUMB WARMER DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
THUMB WARMER RESISTANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.32
HAND WARMER DIAGNOSTICS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33
HAND WARMER RESISTANCE CHECKS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10.33

SPECIFICATIONS
WARNING
Engine Models
PROPOSITION 65 WARNING
Model Number Engine BATTERY POSTS, TERMINALS, AND RELATED ACCESSORIES
CONTAIN LEAD AND LEAD COMPOUNDS, CHEMICALS KNOWN
S4202-6044-OP6N TO THE STATE OF CALIFORNIA TO CAUSE CANCER AND RE-
Domestic L/C 600cc
S4215-6044-OO6N PRODUCTIVE HARM. WASH HANDS AFTER HANDLING.
DC-CFI-4
S4357-6044-OL6N
S4316-6044-OL6G Domestic L/C 600cc BATTERY ELECTROLYTE IS POISONOUS. IT CONTAINS ACID!
S4452-6044-OL6G DC-CFI-2
SERIOUS BURNS CAN RESULT FROM CONTACT WITH THE
S4139-8044-OO8G SKIN, EYES, OR CLOTHING
S4229-8044-OO8G .
S4092-8044-OO8G Domestic L/C 800cc ANTIDOTE:
S4360-8044-OL8G DC-CFI-2 EXTERNAL: FLUSH WITH WATER.
S4361-8044-OL8G
S4359-8044-OL8G INTERNAL: DRINK LARGE QUANTITIES OF WATER OR MILK.
FOLLOW WITH MILK OF MAGNESIA, BEATEN EGG, OR VEGE-
Spark Plugs TABLE OIL. CALL PHYSICIAN IMMEDIATELY.
Gap EYES: FLUSH WITH WATER FOR 15 MINUTES AND GET

Model Spark Plug PROMPT MEDICAL ATTENTION.
(Inches / mm)
2010-2011 NGK BPR9ES BATTERIES PRODUCE EXPLOSIVE GASES. KEEP SPARKS,
.027 / 0.70
2012 DC-CFI-2 NGK GR9A-EG FLAME, CIGARETTES, ETC. AWAY. VENTILATE WHEN CHARG-
ING OR USING IN CLOSED SPACE. ALWAYS SHIELD EYES
Charging/Lighting System WHEN WORKING NEAR BATTERIES.
Model Stator Output # of Pulses KEEP OUT OF REACH OF CHILDREN.

ALL 400W N/A
Ignition Timing
Model Specification
18 @ Idle (1700 RPM
600 DC-CFI-4 [0.95 VDC TPS]) and 120
Engine Coolant Temperature
18 @ Idle (1700 RPM 10
600/800 DC-CFI-2 [0.94 VDC TPS]) and 120
Engine Coolant Temperature

10.3
INSTRUMENT CLUSTER
Overview
ENGINE RPM/VEHICLE SPEED
CK. ENGINE MIL HIGH BEAM
ENGINE TEMP. BRAKE
OIL LEVEL LOW PERC RVS
PERFORMANCE DISPLAY MODE SELECT FUEL LEVEL

VEHICLE INFO. DISPLAY
Information regarding vehicle speed, engine RPM,

engine overheat, PERC, oil level, brake, engine
temperature (2011-current models) and check engine
MIL (diagnostic trouble codes) is transmitted to the gauge
from the ECU using CAN BUS communication
technology.
Current fuel level is received from the fuel level sender
located on the fuel pump. When the high beam headlights
are illuminated, the gauge receives a signal from the YEL/
RED high beam circuit.
The MODE and SEL buttons perform the same functions
as the LH control MODE/SET toggle button.
In addition to standard engine and vehicle information,
the instrument cluster can playback up to three minutes
of historical engine performance, and vehicle speed
information and display diagnostic trouble codes when
the check engine MIL is illuminated.
The instrument cluster is powered by the RED/WHT
chassis power 12 VDC circuit.

Rider Information Display 11. Reverse Indicator - Icon will illuminate and flash
whenever PERC reverse mode button is pushed on
The rider information display is located in the instrument the LH control.
cluster. All segments will illuminate for approximately one
second at start-up. Instrument Cluster Pinouts
NOTE: If the instrument cluster fails to illuminate, an
over-voltage condition may have occurred forcing the
instrument cluster to power down.
1. RPM / Vehicle Speed Display - LCD display of either

engine RPM or vehicle speed in MPH or km/h.
2. MPH / km/h Display - MPH is displayed when the

instrument cluster is in the Standard mode. Km/h is
displayed when the instrument cluster is in the Metric
mode.
Connector Pinouts
3. Performance Information Area - Engine RPM or
Vehicle Speed (whichever is not displayed in top FUNCTION PIN
section of display) / MAX RPM / MAX Ground Speed
and engine temperature (2011 models) are shown in DC Gauge Voltage (VDC) - RED/WHT 1
the middle of the screen. The performance information Ground - BRN/WHT 2
area also displays Play Back when the play back
function is enabled. DC Gauge Voltage (VDC) - RED/WHT 3
CAN 1 High - YELLOW 4
4. Vehicle Information Area - Trip meters A and B /
Odometer / Service Interval Hours / Throttle Opening CAN 1 Low - DK GREEN 5
(TCS). TCS is only available during playback mode.
LH Mode Switch - WHT/RED 10
5. Fuel Level Indicator - Six segment LCD bar graph LH Set Switch - WHT/BLK 11
indicating current fuel level. All segments will flash
when the last segment is cleared indicating a low fuel High Beam Signal - YEL/RED 20
warning. Fuel Level Sensor Signal - VIOLET/WHT 23
6. Check Engine MIL - Illuminated when the ECU has System Ground - BRN/WHT 24
detected a Diagnostic Trouble Code (DTC) within the
engine management system. Icon will flash when DTC NOTE: CAN wires are twisted together and must
display mode is active. remain twisted to prevent interference.
7. Engine Temperature Indicator - LED icon will Engine RPM/Vehicle Speed Display
illuminate when the ECU determines the engine is
overheating. The icon will flash to indicate the engine
is overheating. The icon will stay lit and not flash if a
The top section of the display will show either engine
RPM or vehicle speed. If engine RPM is displayed at the
10
severe overheating condition exists. top, then vehicle speed will be displayed in the
performance information area and vice-versa. To change
8. Low Oil Level Indicator - Icon will illuminate when the the top section display, follow these steps:
oil level in the oil tank becomes too low. Add oil at the 1. The engine RPM or vehicle speed must be displayed
next fuel stop. in the performance information area. If neither are
displayed, press and release the MODE button on the
9. High Beam Indicator - LED will illuminate when the
gauge or LH control until engine RPM or vehicle speed
high beam headlamps are active.
is displayed.
10. Parking Brake Indicator - Icon will illuminate
2. Press and hold the MODE button on the instrument
whenever the brake lever is pulled or when the parking
cluster or LH control for 3 seconds to switch between
brake is engaged.
the two displays.

10.5
Performance Information Area Diagnostic Display
The performance information area (middle) of the display The instrument cluster can display diagnostic trouble
screen is dedicated to displaying: codes (DTCs) when, and only when, the check engine
MIL is illuminated.
Engine RPM or vehicle speed (whichever is not
displayed at the top of the screen) To display DTCs, follow these steps:
Maximum ground speed 1. When an active DTC is realized, the check engine MIL
will illuminate.
Maximum engine RPM
NOTE: The instrument cluster will display historic
Engine temperature (2011-current models only)
DTCs, but only during the same power cycle. All
Press and release the MODE button on the instrument codes stored in the instrument cluster are lost when
cluster or LH control to toggle between the different the instrument cluster is powered down.
displays.
2. Keep the engine running. Press and release the SEL
Vehicle Information Area button on the instrument cluster or the SET switch on
the LH control until the diagnostics mode is activated.
The bottom of the instrument cluster screen is dedicated Once activated, the check engine MIL will begin
to displaying the following information: flashing and Err will be displayed on the screen.
Odometer
3. The diagnostics mode will display the SPN and FMI
Trip A codes. A list of codes can be found in chapter four.
Trip B 4. To check for multiple codes, press and hold the SEL
Engine hours button on the instrument cluster for 2 seconds until a
new code is displayed. Repeat until no new codes are
Press and release the SEL button on the instrument displayed.
cluster or SET button on the LH control to toggle between
the different displays. 5. To exit the diagnostics mode, either turn off the
engine, or press and release the SEL button on the
To reset the Trip A and Trip B displays, press and hold the
instrument cluster.
SEL button on the instrument cluster or SET button on the
LH control for 3 seconds when the desired trip meter is
displayed on the screen. The counter will reset to 0. Playback Mode
NOTE: Engine hours and odometer cannot be reset. The instrument cluster can be used as an engine RPM,
vehicle speed, and TPS data recorder. Once enabled, the
Changing Units gauge can record up to three minutes of information.
To initiate RECORD:
The instrument cluster will display either standard or
metric units. Change between the two by following these 1. Press and hold the MODE and SEL buttons on the
steps: instrument cluster for 3 seconds.
1. Press and release the SEL button on the instrument
2. The PLAY BACK icon will begin flashing when record
cluster or the SET button on the LH control until the
is activated.
ODOMETER is displayed on the screen.
To PLAY BACK:
2. Once the ODOMETER is displayed, press and hold 1. Once the snowmobile has stopped and the engine
either the SEL button or SET button for 3 seconds until RPM drops below clutch engagement speed, press
the units change. and hold the MODE and SEL buttons on the
instrument cluster to enter the play back mode.
2. To exit the play back mode, slightly tap the throttle

lever.

SECURITY SYSTEM Digital Wrench SmartLink Module/Communication
Cables
Security System: Overview
An optional security feature is available on all 2012 Pro-
Ride snowmobiles which is enabled by an authorized
Polaris dealer using Digital Wrench. The security
feature allows the operator to lock the ECU to prevent
unauthorized use. When security is locked the ECU will
prevent clutch engagement by limiting engine speed to
3500 RPM.
NOTE: If the engine is running and security is locked,
the ECU will shut the engine off when the engine
temperature is above 120F (49C) for 60 seconds.
Security System: Digital Wrench Enable The security enable process has to be performed when:
Use Digital Wrench to enable the security function in User wants security function turned on
the ECU. The following list of tools are required to enable
ECU has been reflashed with new reflash fileset
the security function:
Installing a new ECU
PC/Laptop equipped with Digital Wrench and
associated snowmobile SmartLink communication To enable the security function:
cables
1. Open the left side engine compartment door and
Fully Charged 12 VDC Battery locate the Digital Wrench diagnostic plug, ECU
Chassis Power-Up Harness: PS-47296-A power plug, and DC power plug.
Dual Power-Up Adapter: PS-50805

Internet connection to Polaris reflash authorization
site
Chassis Power-Up Harness and Dual PWR/Fuel Pump

Prime Adapter
CHASSIS POWER-UP HARNESS

PS-47296-A
10
2. Connect the dual power-up adapter to the chassis
power-up harness. Attach one of the dual power-up
connectors to the ECM PWR plug, and the other to the
DUAL PWR/FUEL PUMP PRIME DC PWR plug. Connect the alligator clamps to a fully
PS-50805
charged 12 VDC battery.

10.7
3. Start Digital Wrench on the PC/laptop. Navigate to 6. If the security function is not enabled, the following
the appropriate vehicle home page. Select OPTION screen will appear. Highlight the entire REQUEST
6 - SECURITY FUNCTIONS from the Special Tests code and then copy it by pressing (CTRL+C).
(Red Toolbox) Menu.
7. Log on the reflash authorization site at

www.polarisdealers.com. Paste the request code into
4. Select ENABLE SECURITY on the following screen. the field using (CTRL+V). Enter the VIN and customer
information to generate an authorization code.
Reset Passcode
5. After selecting ENABLE SECURITY, Digital

Wrench will scan the ECU to verify the process can 8. Copy the authorization key provided on the
be completed. If the security function is already authorization site by highlighting the entire code and
enabled, Digital Wrench will display the following then pressing (CTRL+C). Go back to Digital
screen. Wrench and paste the Authorization key into the
AUTHORIZATION KEY field by pressing (CTRL+V).
Click CONTINUE.

9. Digital Wrench will begin to reflash the ECU. A timer Security System: Digital Wrench Disable
and status indicator bar on the screen will indicate the
process is working. The security system can be disabled by turning off the
function in the ECU. Select DISABLE SECURITY from
NOTE: Do not disturb the vehicle or computer until the SECURITY FUNCTIONS screen.
this process is complete!
Reset Passcode
10. After the reflash process is complete, cycle the power After selecting Disable Security from the Security
to the ECU by disconnecting and then re-connecting Functions Menu, follow the step-by-step procedure as
the ECU PWR 12 VDC power-up cable. Click the outlined by Digital Wrench. The process is the same as
FINISH button. the Enable Procedure.
11. The following screen will appear. Click on the red X.
10
12. Determine if the Instrument Cluster Initialization

procedure has to be completed by starting the engine,
setting the parking brake, and then pressing and
holding the MODE and SEL buttons on the instrument
cluster.

10.9
Security System: Digital Wrench Passcode 3. Start Digital Wrench on the PC/laptop. navigate to
Reset the appropriate vehicle home page. Select OPTION
5 - SECURITY FUNCTIONS from the Special Tests
If the three digit passcode is either lost or unknown, it can (Red Toolbox) Menu.
be reset to 000 using Digital Wrench.
The ECU and instrument cluster must be powered at the
same time. This can be done by either starting and
running the engine in a well-ventilated area, or with the
chassis power-up harness and dual power-up adapter.
Steps 1 and 2 can be eliminated by performing the
procedure with the engine running.
When using the chassis power-up harness and dual
power-up adapter to reset the password, follow these
steps:
locate the Digital Wrench diagnostic plug, ECU
power plug, and DC power plug. 4. Select RESET PASSCODE on the following screen.
Reset Passcode
5. Digital Wrench will reset the instrument cluster

passcode to 000. During the process the instrument
2. Connect the dual power-up adapter to the chassis cluster display, oil level, and engine temp. MIL LEDs
power-up harness. Attach one of the dual power-up will flash.
connectors to the ECM PWR plug and the other
connector to the DC PWR TEST plug. Connect the
alligator clamps to a fully charged 12 VDC battery.
NOTE: The ECU and DC chassis power circuits
(instrument cluster, LED brake, etc) are now powered.
Confirm the instrument cluster is powered-up.

6. After the reset passcode process is complete, the Security System: Instrument Cluster
following screen will be displayed. Click on the Initialization
RETURN button to return to the main screen.
Instrument cluster initialization is a one-time procedure
that must be performed when the instrument cluster is
linked for the first time to a security-enabled ECU.
The ECU and instrument cluster must be powered at the
same time. This can be done by either starting and
running the engine in a well-ventilated area, or with the
chassis power-up harness and dual power-up adapter.
Skip steps 1 and 2 when performing the procedure with
the engine running.
When using the chassis power-up harness and dual
power-up adapter, follow these steps:
7. Cycle the power to the ECU and DC PWR test locate the Digital Wrench diagnostic plug, ECU
connectors to finish the procedure. power plug, and DC PWR test plug.
2. Connect the dual power-up adapter to the chassis

power-up harness. Attach one of the dual power-up
connectors to the ECM PWR plug and the other
connector to the DC PWR TEST plug. Connect the
alligator clamps to a fully charged 12 VDC battery.
NOTE: The ECU and DC chassis power circuits 10
(instrument cluster, LED brake, etc) are now powered.
Confirm the instrument cluster is powered-up.

10.11
3. Hold the brake lever. Press and hold the MODE and 5. SECURE ON will be displayed. The display will
SEL buttons for 3 seconds, then release. SECURE alternate between SECURE ON and ENTER CODE.
OFF should be displayed. If not, repeat this step.
6. Wait until ENTER CODE displays, then press and

4. Wait until ENTER CODE displays, and then press and release MODE button 3 consecutive times to enter
release MODE button 3 consecutive times to enter and accept the 000 digit base code.
and accept the 000 base code.
NOTE: If the ENTER CODE screen exits due to
inactivity, repeat step 3.
PRESS MODE
PRESS MODE
PRESS MODE
PRESS MODE
PRESS MODE
PRESS MODE
ENTER AND EXIT
ENTER AND EXIT
NOTE: Security is now LOCKED.

7. SECURE OFF displays if the system unlocks. Security System: Locking
1. Start the engine in a well ventilated area.
2. Hold the brake lever. Press and hold the MODE and
SEL buttons for 3 seconds, then release. SECURE
OFF should be displayed. If not, repeat this step.
8. Immediately after locking and unlocking the security

system, and while SECURE OFF is displayed, press
and hold the MODE button to bring up the enter code
screen.
9. When ENTER CODE displays, use the MODE and

SEL = Advances up 1 digit (0 to 9 to 0)
SEL buttons to select and accept each digit of a new
personal security code. MODE = Enter and move 1 digit to right
SEL = Advances up 1 digit (0 to 9 to 0) 3. When ENTER CODE displays, press and release SEL
to advance the digit. When the first digit of your
MODE = Enter and move 1 digit to right
security code is displayed, press and release the
10. After pressing MODE to accept the last digit, view the MODE button to accept the digit and move to the next
display screen. The new code and CODE SET will digit.
display if the system accepted the new code. If
successful, you will not see this screen again.
NOTE: If the ENTER CODE screen exits due to

inactivity, repeat the locking procedure.
NOTE: If steps 9-11 are not completed immediately
after performing the initialization procedure, the 4. Continue to use MODE and SEL to select and accept
security code will be 000. See Changing Security Code the remaining two digits of the security code.
to enter a new passcode.
11. Record the new security code in a safe place (Owners

5. After pressing MODE to accept the last digit, view the
display screen. SECURE ON displays if the system
10
locks. Engine RPM speed is now limited and the
Manual or Customer RO) for future reference.
snowmobile cannot be driven.

10.13
NOTE: When the engine is running and security is Security System: Unlocking
locked, the display will alternate between SECURE ON
and ENTER CODE. 1. When the engine is running and security is locked, the
display will alternate between SECURE ON and
ENTER CODE.
NOTE: When the system is locked and the engine
temperature is above 120F (49C), the correct pass
code must be entered within 60 seconds or the engine
will shut down.
SEL = Advances up 1 digit (0 to 9 to 0)

MODE = Enter and move 1 digit to right
6. If an incorrect code is entered, BAD CODE will be
displayed. Wait until the display returns to the ENTER 2. When ENTER CODE displays, press and release
CODE screen and then re-enter the correct passcode. SEL to advance the digit. When the first digit of your
security code is displayed, press and release MODE
to accept the digit and move to the next digit.
3. Continue to use MODE and SEL to select and accept

the remaining two digits of the code.
4. After pressing MODE to accept the last digit, view the

display screen. SECURE OFF displays if the system
unlocks.
5. If an incorrect code is entered, BAD CODE will be

displayed. Wait until the display returns to the ENTER
CODE screen and then re-enter the correct passcode.

Security System: Changing Passcode Security System: User Notes
To change the current security code to a new code, Security system activation requires an authorized
perform these steps: Polaris dealer using Digital Wrench to turn on
the function in the ECU.
NOTE: The instrument cluster illustrations on the
following pages reference the 000 default security First time use requires an initialization procedure
code. Use the owners current security code. to turn on the security function in the instrument
cluster.
1. Start the engine and lock the parking brake.
Holding the brake lever closed and pressing the
2. Lock and then unlock the security function on the MODE and SEL buttons for 3 seconds will bring up
instrument cluster using the existing passcode. the security display on the instrument cluster.
If the brake lever is not held while pressing the
3. Immediately after unlocking security, press and hold
MODE and SEL buttons for 3 seconds, the
the MODE button to display the ENTER CODE
instrument cluster will start the record/playback
screen.
data logging function.
SEL = Advances up 1 digit (0 to 9 to 0) Pressing the MODE button will accept the selected
MODE = Enter and move 1 digit to right digit and move to the next digit. After entering the
third digit, pressing MODE a fourth time will enter
4. When ENTER CODE displays, use the MODE and the code.
SEL buttons to select and accept each digit of the new Pressing the SEL button advances each digit up
security code. from 0 to 9 then back to 0.
5. After pressing MODE to accept the third digit, the new If the engine is running and security is locked, the
code and CODE SET will display if the system ECU will shut the engine off when the engine
accepted the new code. If successful, this screen will temperature is above 120F (49C) for 60
not be displayed again. seconds.
The instrument cluster retains the last
programmed security passcode. Disabling and
enabling the security function in the ECU does not
change the code in the insturment cluster. If the
passcode is unkown or BAD CODE is displayed
perform the Reset Passcode Procedure to reset
the code back to 000.
Reflashing the ECU using the Engine Controller
Reprogramming function disables the security
6. Record the new security code in a safe place (Owners function. Perform the Security Enable procedure
Manual or Customer RO) for future reference. after reflashing the ECU.
10

10.15
MAINTENANCE-FREE BATTERY 4. Remove the rubber strap. Disconnect the RED(+)
cable first, and then the BLACK(-) cable.
Specifications
5. Installation is the reverse of removal. Install the
Battery PN 4012638 BLACK(-) cable first, and then the RED(+) cable
during installation.
Battery Type Yuasa - YTX20CH-BS
Battery Preparation
12VDC / 18AH @ 10hr.
Nominal Capacity
rate.
Electrolyte Volume 28oz. WARNING
Specific Gravity 1.340
WEAR PROTECTIVE GLOVES AND EYEGLASSES
CCA @ 0F (-18C) 270 AMPS WHEN SERVICING THE BATTERY.
Charging Current 1.8 AMPS (5-10 Hours) NOTE: Do not service the battery unless it will be put
into regular service within 30 days.
Specifications
Some original equipment and service batteries are
Battery PN 4013045 supplied with acid packs.
Yuasa - YTX20CH
Battery Type
(Sealed)
12VDC / 18AH @ 10hr.
Nominal Capacity
rate.
Electrolyte Volume 28oz.
Specific Gravity 1.340
CCA @ 0F (-18C) 270 AMPS
Charging Current 1.8 AMPS (5-10 Hours)
Battery Removal/Installation
1. To fill the dry battery, remove the vent cap from the
battery and the sealing cap from the acid pack.
SILENCER
Carefully tip the acid pack into the battery vent ports.
STRAP
2. Set battery aside and allow it to cool and stabilize for
HEAT SHIELD at least 30 minutes. Reinstall the battery vent cap.
NOTE: This is the last time that electrolyte should be
added.
3. Charge battery at 1/10 of its amp/hour rating.

Example:1/10 of 9 amp battery =.9 amps, 1/10 of 14
amp battery = 1.4 amps, 1/10 of 18 amp battery = 1.8
amps (recommended charging rates).
4. Check specific gravity of each cell with a hydrometer

to ensure each has a reading of 1.270 or higher.
1. Open the left and right side door panels. Remove the 5. Install vent cover.
hood.
NOTE: Once the vent cover is installed, the battery is
2. Remove the exhaust silencer. sealed. Do not remove the cover.
3. Remove the battery heat shield.

Charging Procedure OCV - Open Circuit Voltage Test
If battery voltage is 12.6 VDC or less, the battery may Battery voltage should be checked with a digital
need recharging. When using an automatic charger, refer multitester. Readings of 12.6 volts or less require further
to the charger manufacturers instructions for recharging. battery testing and charging. See the following chart and
Load Test.
Do not exceed 10 amps when charging the battery.
NOTE: Maintenance Free batteries should be kept at
NOTE: Charge the battery using an automatic
a high state of charge during storage. If the battery is
charger that will not exceed 14.6 VDC. An automatic
stored or used at a low state of charge, hard crystal
charger will signal when charging is complete.
sulfation will form on the plates, reducing the
efficiency and service life of the battery.
Allow the battery to stand disconnected for several
hours after being properly charged. If the voltage NOTE: Use a volt/ohm meter to test battery voltage.
drops below 12.6 volts, charging was ineffective or the
battery needs to be replaced.
OPEN CIRCUIT VOLTAGE
State of Charge Maintenance Free
WARNING
100% 12.8 V and up
An overheated battery could explode, causing severe
injury or death. Always watch charging times carefully. 75% Charged 12.6 V
Stop charging if the battery becomes very warm to the
50% Charged 12.3 V
touch. Allow it to cool before resuming charging.
25% Charged 12.0 V
Battery Charging Reference Table 0% Charged 11.8 V or less
State of Charge
Charge
Voltage (DC) Action
Time
Load Test
None, check
None CAUTION
100% 12.8 or more again in 3
Required
months
75% - May need To prevent shock or component damage, remove spark
12.6 - 12.8 3 - 6 hrs plug high tension leads and connect securely to
100% slight charge
engine ground before proceeding.
50% - 75% 12.3 - 12.6 Needs Charge 5 - 11 hrs
At least A battery may indicate a full charge condition in the OCV
25% - 50% 12.0 - 12.3 Needs Charge test, but still may not have the storage capacity necessary
13 hrs
to properly function in the electrical system. For this
At least
0% - 25% 12.0 or less Needs Charge reason, a battery capacity or load test should be
20 hrs
conducted whenever poor battery performance is
NOTE: Follow the charger instructions supplied by
the manufacture regarding the order or connections,
encountered.
To perform this test, use a load testing device that has an
10
switch positions and when to connect the charger to adjustable load. Apply a load of three times the ampere-
an outlet. hour rating. At 14 seconds into the test, check battery
voltage. A good 12V battery will have at least 10.5 volts.
Battery Testing If the reading is low, charge the battery and retest.
Whenever a service complaint is related to either the

starting or charging systems, the battery should be
checked first.
Following are two tests which can easily be made on a
sealed Maintenance Free battery to determine its
condition: OCV Test and a Load Test.

10.17
Battery Conductance Analyzer Battery Off Season Storage
Conductance describes the ability of a battery to conduct Whenever the vehicle is not used for a period of three
current. A conductance tester functions by sending a low months or more, remove the battery from the vehicle,
frequency AC signal through the battery and a portion of ensure that it's fully charged, and store it out of the sun in
the current response is captured, from this output a a cool, dry place. Check battery voltage each month
conductance measurement is calculated. Conductance during storage and recharge as needed to maintain a full
testing is more accurate than voltage, specific gravity, or charge.
load testing.
NOTE: Battery charge can be maintained by using a
Authorized Polaris dealers/distributors are required to Polaris battery tender charger or by charging once a
use the conductance analyzer when testing 12V Polaris month to make up for normal self-discharge. Battery
batteries. tenders can be left connected during the storage
period, and will automatically charge the battery if the
voltage drops below a pre-determined point.
Polaris MDX-610P
SPX PN: PU-50296

ELECTRIC START
System Schematic
DC--CFI ECU CNA CONNECTOR
3 1
DG/WH
RED/BLK
KEY SWITCH
10A BREAKER (CIRCUIT CLOSED
WHEN KEY TURNED
TO START)
WHITE
CHASSIS/ELECTRIC START HARNESS
CONNECTOR
WH/RD
STARTER SOLENOID
RED RD/DK RED
M
STARTER
MOTOR
RED
AC REGULATOR
BATTERY CHARGE
GROUND
- +
BATTERY
10
RED BATTERY CHARGE
10A PROTECTED
RD/DK
DCV
BRN -- DIRECT CH / ENG GROUND
AC STATOR
YELLOW
VOLTAGE

10.19
Starter Motor/Flex Drive Assembly
STARTER MOTOR
WORM GEAR CLAMP
C B
FLEX DRIVE
B PINION/PINION BRACKET
END PLATE MOUNTING BRACKET
4. To remove the starter motor, remove the gear clamp,

CAUTION and then the two-rear starter motor mount nuts.
5. During assembly, install the flex drive on to the pinion

Disconnect battery before servicing starter motor
assembly. Install the three pinion assembly screws
components.
and torque to specification.
Always remove RED(+) battery cable first, and then
BLACK(-) cable. Reverse order during battery 6. Loosely fit the gear clamp around the motor, and then
installation. install the flex drive on to the motor shaft.
7. Torque the rear nuts to specification.

=T
8. Torque the gear clamp hand tight.
A = 22 ft-lb (30 Nm)
B = 7 ft-lb (10 Nm) 9. Reinstall the y-pipe. Torque fasteners to specification.
C = 8 ft-lb (11 Nm)
10. Reinstall the silencer and exhaust pipe.
Starter Motor/Flex Drive Service
The starter motor, flex drive, and pinion gear can be
serviced with the engine in the snowmobile.
1. Remove the exhaust pipe. If servicing the motor,
remove the silencer.
2. When servicing the pinion gear, remove the y-pipe.
3. Using a ball-end allen wrench, remove the 3 screws

attaching the pinion assembly to the engine.

Battery Box Assembly
POSITIVE CABLE (SOLENOID TO STARTER MOTOR)
POSITIVE CABLE (SOLENOID TO BATTERY)
CIRCUIT BREAKER LEAD
B A CIRCUIT BREAKER
GROUND CABLE B
A
A
A
SOLENOID
BATTERY A
HEAT SHEILD
STRAP
A BATTERY BOX
10
CAUTION
Always disconnect RED(+) battery cable first, and then

BLACK(-) cable. Reverse order during battery
installation.
=T
A = 7 ft-lb (10 Nm)
B = 8 ft-lb (11 Nm)

10.21
IGNITION TIMING 8. If the pointer is outside the variance, either the
flywheel key has sheared allowing the flywheel to
Timing Procedure move on the crankshaft, the crankshaft is out of index,
a problem with the engine electrical harness exists, or
NOTE: Before performing procedure, verify there are one of the crankshaft position sensors has moved.
no current trouble codes and that all of the engine
electrical connections are clean and tight.
1. Reference the timing specification chart and locate

the piston BTDC measurement for 18.
2. Install a dial indicator gauge into the MAG spark plug

hole.
3. Place the MAG piston at 18 BTDC. Mark the flywheel.

NOTE: Each 10 degree mark is separated by lines
every 2 degree. Acceptable timing variance is +/- 2
degrees.
Flywheel
Rotation
4. Connect timing light to the engine according to

manufacturer's instructions.
5. Start and run the engine at idle speed until the engine
temperature is 120F (49C). Verify the throttle lever
is closed and the engine is at idle speed (1700 +/- 100
RPM).
NOTE: The engine temperature must be
approximately 120F (49C) to obtain accurate timing
specification.
6. Point the timing light at the timing inspection hole.
7. With your head positioned so there is a straight line

between your eye, the stationary pointer and the
crankshaft center line, note the relative position
between the marked flywheel line and the pointer. If
the stationary pointer is aligned with the mark made
in Step 3, or within the acceptable variance, ignition
timing is correct.
NOTE: The stator plate, two-tooth, and five-tooth
crankshaft position sensor locations are not
adjustable.

Ignition Timing Chart BTDC to either inches or millimeters, then use a dial
Convert the ignition timing specification from degrees indicator to verify timing marks.
600 DC-CFI-2/4 800 DC-CFI-2

ROD/STROKE (mm)
128mm ROD / 64mm STROKE 132mm ROD / 70mm STROKE
Degrees BTDC MM Inches MM Inches
1 0.0061 0.0002 0.0067 0.0003
2 0.0244 0.0010 0.0270 0.0011
3 0.0548 0.0022 0.0607 0.0024
4 0.0974 0.0038 0.1078 0.0042
5 0.1522 0.0060 0.1684 0.0066
6 0.2190 0.0086 0.2424 0.0095
7 0.2979 0.0117 0.3298 0.0130
8 0.3889 0.0153 0.4305 0.0169
9 0.4919 0.0194 0.5445 0.0214
10 0.6068 0.0239 0.6717 0.0264
11 0.7336 0.0289 0.8121 0.0320
12 0.8723 0.0343 0.9656 0.0380
13 1.0227 0.0403 1.1321 0.0446
14 1.1849 0.0466 1.3115 0.0516
15 1.3586 0.0535 1.5038 0.0592
16 1.5439 0.0608 1.7089 0.0673
17 1.7406 0.0685 1.9266 0.0758
18 1.9487 0.0767 2.1569 0.0849
19 2.1681 0.0854 2.3996 0.0945
20 2.3986 0.0944 2.6547 0.1045
21 2.6402 0.1039 2.9220 0.1150
22 2.8927 0.1139 3.2013 0.1260
23 3.1560 0.1243 3.4927 0.1375
24 3.4300 0.1350 3.7958 0.1494
25 3.7146 0.1462 4.1106 0.1618
26 4.0096 0.1579 4.4369 0.1747
27 4.3149 0.1699 4.7746 0.1880
28 4.6303 0.1823 5.1235 0.2017
29 4.9558 0.1951 5.4835 0.2159
30 5.2911 0.2083 5.8543 0.2305
31 5.6361 0.2219 6.2358 0.2455
32 5.9907 0.2359 6.6278 0.2609
33
34
6.3546
6.7278
0.2502
0.2649
7.0302
7.4427
0.2768
0.2930
10
35 7.1099 0.2799 7.8652 0.3097
36 7.5010 0.2953 8.2974 0.3267
37 7.9007 0.3111 8.7392 0.3441
38 8.3089 0.3271 9.1903 0.3618
39 8.7254 0.3435 9.6506 0.3799
40 9.1501 0.3602 10.1198 0.3984

10.23
DC-CFI ELECTRICAL SYSTEMS
DC-CFI Stator Assembly
DC-CFI Stator Specifications

RESISTANCE
ITEM COLOR SYSTEM FUNCTION
+/- 15% @68F (20C)
14VAC Chassis Power
- Battery Charge (Electric Start Equipped) YELLOW TO YELLOW = 0.12
AC Lighting Coil (Y) YELLOW to YELLOW
- Head / Tail Lights NO CONTINUITY TO GROUND
- Hand / Thumb Warmers
14VDC Chassis Power
- Fuel Pump
YELLOW TO YELLOW = 0.20
DC Chassis Coil (Z) YELLOW to YELLOW - Chassis Relay Coil
NO CONTINUITY TO GROUND
- EV Solenoid
- Instrument Cluster
16 VDC System Power
- Fuel Injector Power ORANGE TO ORANGE = 0.72
DC System Coil (X) ORANGE to ORANGE
- ECU / Sensor Power (Regulated to 5VDC) NO CONTINUITY TO GROUND
- Ignition Coil Power
GRN to WHT/GRN Crank Position Sensor (5 Tooth) Ignition timing GRN to WHT/GRN = 190
CRANK POSITION SENSOR (CPS) Crank Position Sensor (2 Tooth)
WHT to WHT/RED WHT to WHT/RED = 190
Locates TDC and RPM
ENGINE GROUND BROWN Engine Ground 0

DC Regulator/Rectifier DC-CFI AC Regulator/Battery Charge
Rectifier
DC-CFI models feature an AC regulator/DC (battery
charge) rectifier. The AC regulator/battery charge rectifier
only regulates AC voltage and charges the battery (when
equipped). It does not supply VDC to the instrument
cluster or accessory power points.
DC-CFI Regulator / Rectifier Connections

WIRE
CONNECTOR ITEM
COLORS Circuit Specifications
Stator YELLOW VAC from stator coils.
PLUG/PIN/COLOR FUNCTION
VDC supplied to ECU to
ECU ORANGE boost power to fuel pump 1 - RED/DK. GREEN 14.7DCV BATTERY (+)
during engine start-up.
2 - YELLOW 14.3 ACV (FROM STATOR)
BROWN 14.5 VDC Chassis power.
Chassis (Instrument cluster/EV 3 - BROWN GROUND (-)
RED solenoid/DC power points)
DC-CFI Chassis Power Capacitor
10
Capacitor Testing
1. Charge the capacitor for 10 seconds using a 12 volt
battery by connecting the positive (+) lead to the Red/
White wire and the negative (-) lead to the brown wire.
2. Monitor the capacitor voltage with a multimeter. The

voltage should slowly drain down from the initial
charge. If the cap does not hold a charge or drains
rapidly, replace the component.

10.25
Ignition Coil Packs Oil Level Sender
FULL EMPTY (CONTINUITY)

Specifications
To test the oil level sender, position the sender as it would
600/800 be in the oil tank. Allow the float to drop in the direction it
Coil Pack 600 DC-CFI-4
DC-CFI-2 would if the oil tank were empty. Continuity should be
Wires/Leads
+/- 15% @ 68F (20C) present when using a multimeter to test the sender with
the float in the empty position.
BLACK to WHITE
0.20 0.45 No continuity should be present when the float is moved
(Primary)
away from the empty position.
BLACK to
6.3K 18K
Secondary Lead
LH Control Assembly
Plug cap 5K
Test the left hand (LH) control assembly using a
multimeter set to show continuity. Reference the
Exhaust Valve Solenoid illustration below for continuity checks.
Specifications
Coil Resistance
15 +/- 15% @ 68F (20C)
(WH/YE to RED)

DC-CFI Regulated (Red) Power Circuits
DC--CFI ECU 3 4 P I N CNA CONNECTOR
20 21 30 34 17 19 33
ORG WH/DB
ORG
BRN/YEL
WHT/YEL RED
RED ORG
DIGITAL
WRENCH
PLUG
RED/WHT
CHASSIS RELAY
FUEL
EV SOLENOID ORG PUMP
PRIME
PLUG
RED
M RED
REGULATOR
RECTIFIER FUEL PUMP
EXT.
POWER
PLUG
CAPACITOR
ORG
10
RED/WHT DC CHASSIS VOLTAGE
RED REGULATED DC
VOLTAGE
YELLOW AC STATOR
VOLTAGE
ORANGE EXTERNAL POWER

10.27
DC-CFI Chassis (Red/White) Power Circuits
DC--CFI ECU 3 4 P I N CNA CONNECTOR
BN/WH
RD/WH 1 INSTRUMENT CLUSTER 2
POWER
11
RD/WH 3 28
BN/WH
DC POWER BROWN
RD/WH TEST PLUG
OR/BK
2 AMP FUSE
RD/WH ACCESSORY POWER
RD/YE
PLUG
BROWN
ORANGE
BRAKE SWITCH
RED/WHT DC VOLTAGE
FROM CHASSIS RELAY
RED REGULATED
DC VOLTAGE

DC-CFI AC Power (Lighting) Circuits
INSTRUMENT CLUSTER
20
YE/RD
YE/RD
HEAD LIGHTS
YE/RD
BRN
THUMB WARMER HAND WARMERS
DG/YEL
BLU/RED
BLUE
GRY/WHT
ORG/GRN
YELLOW
DG/YEL
YE/RD BRN/WHT
BRN/WHT 10
BRN
AC REGULATOR AC
RECTIFIER POWER
TEST
RED/GRN BATTERY VOLTAGE
YELLOW AC STATOR VOLTAGE
BROWN GROUND
BRN/WHT SWITCHED GROUND

10.29
DC-CFI Throttle/Ignition Kill System
DC--CFI ECU CNA CONNECTOR
25 9 7 15 16
BLACK
IGNITION SWITCH
(SWITCH CLOSED WHEN KEY
TURNED TO OFF)
BLK/RED
TETHER SWITCH
(CLOSED WHEN TETHER
REMOVED)
OPTIONAL
2148
THROTTLE LEVER SWITCH SAFETY SLAP SWITCH
(PUSHED = CLOSED)
2148 OHMS = SWITCH CLOSED/LEVER REL.
6788 OHMS = SWITCH OPEN/LEVER PUSHED
4640
BLK/BLU SENSOR GROUND
CHASSIS / ENGINE
BRN GROUND
System Overview A hardware stop system is a direct ignition kill system.

That is, whenever the operator turns the key to off, pulls
A software stop is used to determine the position of the
the tether, or pushes the safety slap switch down, the
throttle flipper switch. The software stop system is
ignition system is immediately killed.
activated when the throttle flipper switch is closed (closed
throttle), but the TPS (throttle plate position) is still above
idle. When this occurs, the ECU software will determine
the throttle cable is stuck and kill the ignition system.
To test the throttle lever, measure the resistance with the
lever pushed and closed and compare results to those in
illustration.
Always verify the throttle lever freeplay is set to
specification.

DIAGNOSTIC PLUGS DC PWR Plug
Connect the Chassis Power-Up Harness to the DC PWR
Power Test Plugs
plug to supply battery power to the following components:
Instrument cluster
DC accessory power points
LED tail lamp/brake lamp
ECM PWR Plug

FUEL PUMP PRIME
Connect the Chassis Power-Up Harness to the ECM
PWR plug to supply battery voltage to the following
components:
Digital Wrench communication connector
ECU
Chassis relay driver coil
A set of power test and fuel pump prime plugs allows a VES solenoid
technician to test several electrical circuits on the DC Power capacitor
snowmobile.
Fuel pump power side
The plugs can be accessed behind the left door panel.
NOTE: The AC power test plug is located on the Fuel Pump Prime Plug
handlebar wiring harness on 2011-later models. Use the Chassis Power-Up Harness and Dual PWR/Fuel
Pump Prime Adapter to supply battery voltage to the fuel
Shown below is the Chassis Power-Up Harness,
pump. This is useful for purging the fuel system of air or
PS-47269-A, and Dual Power/Fuel Pump Prime Adapter,
testing fuel pump pressure with the engine off.
PS-50805.
When both tools are used together, the technician can
AC PWR Plug
supply power to the ECM PWR and DC PWR plugs. This
is required for enabling the security function on 2012 CAUTION
models. Also, the Dual PWR/Fuel Pump Prime Adapter
can connect to the fuel pump prime plug. DO NOT CONNECT BATTERY VOLTAGE TO THE AC
PWR TEST PLUG. SEVERE ELECTRICAL SYSTEM
CHASSIS POWER-UP HARNESS
DAMAGE WILL OCCUR.
PS-47296-A
The AC circuits can be tested with a multimeter at the AC
PWR plug. AC circuits include the head lights, hand
warmers, and thumb warmer. 10
NOTE: The AC power test plug is located on the
handlebar wiring harness on 2011-later models.
DUAL PWR/FUEL PUMP PRIME

PS-50805

10.31
HAND/THUMB WARMERS
MOLEX CONNECTOR
Thumb Warmer Diagnostics
The thumb warmer on all Polaris snowmobiles is a
thermistor-type warming element pad. This means its
resistance will change based on temperature.
Thumb Warmer Resistance Checks
RESISTANCE @ ROOM
CIRCUIT (Wire Color)
TEMP. (68 F / 20 C)
LOW (ORANGE/GRAY) to
1 - 120
GROUND (BROWN)
HIGH (WHITE/GRAY) to
1 - 120
GROUND (BROWN)
LOW or HIGH to CHASSIS
O.L. (OPEN CIRCUIT)
(SHORT)
PACKARD CONNECTOR

Hand Warmer Diagnostics Hand Warmer Resistance Checks
There are two types of hand warmer element pads used NOTE: Hand warmer pads do not feature a high
on Polaris snowmobiles. One version is used on steel/ temperature circuit. On snowmobiles featuring a left-
painted handlebars and touring model rear passenger hand control, high temperature is achieved by
grab bars, while the other is used on aluminum (Pro supplying power to both the low and medium circuits.
Taper) handlebars. The difference between the two hand On snowmobiles featuring console-mount controls,
warmer element pads is in the resistance values. A lower the medium circuit is the high temperature circuit.
resistance element pad is used on aluminum bars
because aluminum dissipates heat faster than steel.
RESISTANCE @ ROOM
CIRCUIT (Wire Color)
A common misconception with Polaris hand warmer TEMP. (68 F / 20 C)
elements is the higher resistance circuit is the high
STEEL HANDLEBARS
temperature element. In reality, the hand warmer circuit
with the least amount of resistance will flow more current, LOW (BLUE) to GROUND
20.5 +/-10%
and thus create more heat. This is an important fact that (BROWN)
must be taken into consideration when performing MEDIUM (BLUE/RED) to
resistance checks on a set of hand warmers. 13 +/-10%
GROUND (BROWN)
For example, if a customer has a concern that the left LOW or MEDIUM to CHASSIS
O.L. (OPEN CIRCUIT)
hand warmer appears to be cooler than the right, the (SHORT)
technician should compare the resistance readings of
ALUMINUM HANDLEBARS
each pad to the specifications, and then between the left
and right pads. If the resistance of the left pad is LOW (BLUE) TO GROUND
10 +/-10%
significantly higher than that of the right, more current will (BROWN)
flow to the right side. While more common reasons for MEDIUM (BLUE/RED) to
this can be attributed to how the customer holds the bar 5 +/-10%
GROUND (BROWN)
in their hands (fingers on brake lever and not wrapped
LOW or MEDIUM to CHASSIS
around grip, etc.), there may be instances where O.L. (OPEN CIRCUIT)
(SHORT)
comparing the left and right hand warmer resistance
values may resolve the customer's concern.
Another issue is when one or both of the element circuits
shorts to the handlebar itself. This can occur either
because the pad was improperly installed, solder breaks,
or if the grip moves on the bar.
STEEL HANDLEBARS
10
ALUMINUM HANDLEBARS

10.33
NOTES

2010 RUSH Chassis Harness 1 of 2
2010 600 RUSH Chassis 2 of 2
2010 RUSH Hood Harness
2010 RUSH Engine Harness
2011 PRO-RIDE 600 STD.
Chassis Harness 1 of 2
2011 600 PRO-RIDE STD.Chassis Harness 2 of 2
2011 PRO-RIDE 800 STD. Chassis Harness 2 of 2
2011 PRO-RIDE 800 Premium
5
10
5
10
2011 PRO-RIDE 800 Premium Chassis Harness 2 of 2
2011 PRO-RIDE Hood Harness
2011 PRO-RIDE 600 4 Injector Engine Harness
2012 600 STD.Chassis Harness 2 of 2
2012 PRO-RIDE 800 STD. Chassis Harness 2 of 2
2012 PRO-RIDE 600/800 Premium
5
10
5
10
2012 PRO-RIDE 600/800 Premium Chassis Harness 2 of 2
2012 PRO-RIDE Hood Harness
2012 PRO-RIDE 600/800 2 Injector Engine Harness

2010-12 600 800 Rush Switchback RMK Service Manual PDF

Uploaded by

Copyright:

Available Formats

2010-12 600 800 Rush Switchback RMK Service Manual PDF

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

2010-12 600 800 Rush Switchback RMK Service Manual PDF

Uploaded by

Copyright:

Available Formats

General Information

9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

ALTITUDE DRIVE CLUTCH P2 DRIVEN CLUTCH

Stroke (inches/mm) 2.52 / 64 Drive Clutch Bolt Torque: 80 lb.ft. (108Nm)

Idle RPM 1700 0-600

1.2 9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

Piston to Cylinder 0-600

Engagement RPM 200 3800 2400-3000

Throttle Body Bore 46mm Track

1.4 9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

Spark Plug NGK BPR9ES Spring length set to rider weight

9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

Fuel Delivery Brake Fluid DOT 4

1.6 9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

Width - Inches (cm) 15 (38) Suspension Type PRO-RIDE Progressive 1

NOTE: * = Rider weight in everyday clothing.

9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

Displacement / # Cylinders 794cc / 2 Drive Clutch Bolt Torque: 80 lb.ft. (108Nm)

1.8 9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

Width (in/cm) 48 / 121.9 Suspension Type PRO-RIDE 1

Electrical FTS Spring Rate

9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

Piston to Cylinder Drive Clutch Bolt Torque: 80 lb.ft. (108Nm)

1.10 9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

Width - Inches (cm) 15 (38) Suspension Type RMK Coil-Over 155 1

Track tension sag in/cm Rear Track Shock

9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

Liberty Liquid-Cooled / 600-1200

Type - Number of Fuel Estimated Dry Weight (lb/kg) 446 / 202.3

1.12 9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

Width - Inches (cm) 15 (38) Suspension Type RMK Coil-Over 155 1

Track tension sag in/cm FTS Spring Installed

9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

Displacement / # Cylinders 794cc / 2 Drive Clutch Bolt Torque: 80 lb.ft. (108Nm)

Fuel Delivery Fuel (Gallons / Liters) 11.5 / 43.5

1.14 9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

Width - Inches (cm) 15 (38)

Track tension sag in/cm FTS Spring Installed

9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

Displacement / # Cylinders 599cc / 2 Drive Clutch Bolt Torque: 80 lb.ft. (108Nm)

1.16 9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

Spark Plug NGK BPR9ES Spring length set to rider weight

9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

Displacement / # Cylinders 794cc / 2 Drive Clutch Bolt Torque: 80 lb.ft. (108Nm)

1.18 9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

Width - Inches (cm) 15 (38) Suspension Type PRO-RIDE Progressive 1

9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

Type - Number of Fuel Estimated Dry Weight (lb/kg) 465 / 211

1.20 9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

Width - Inches (cm) 15 (38) Suspension Type PRO-RIDE Progressive 1

Ski Center Distance Rear Travel

9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

Installed Ring Gap 600-1200

Engagement RPM 200 3800 2400-3000

Fuel Octane (R+M/2) Pitch 2.52

1.22 9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

Fuel Delivery Brake Fluid DOT 4