Polaris 2010 Rush User Manual

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Pantone 425C

WARNING

Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels.

Failure to follow the safety precautions could result in serious injury or death.

WARNING

The engine exhaust from this product contains chemicals known to the State of California to cause cancer, birth defects or other reproductive harm.

The text is printed on 100% recycled

with 40% post-consumer waste (PCW).

Pantone 425C

For your nearest Polaris dealer, call 1-800-POLARIS or visit www.polarisindustries.com Polaris Sales Inc., 2100 Hwy. 55, Medina, MN 55340 Phone 1-888-704-5290 Part No. 9922276 Rev 02 Printed in USA

WELCOME

Thank you for purchasing a Polaris vehicle, and welcome to our worldwide family of Polaris enthusiasts. Be sure to visit us online at www.polarisindustries.com for the latest news, new product introductions, upcoming events, career opportunities and more.

Here at Polaris we proudly produce an exciting line of utility and recreational products.

• Snowmobiles

• All-terrain vehicles (ATVs)

• RANGER utility vehicles

• Victory motorcycles We believe Polaris sets a standard of excellence for all utility and recre-

ational vehicles manufactured in the world today. Many years of experience have gone into the engineering, design, and development of your Polaris vehicle, making it the finest machine we've ever produced.

For safe and enjoyable operation of your vehicle, be sure to follow the instructions and recommendations in this owner's manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the Polaris Service Manual and should be performed only by a Factory Certified Master Service Dealer (MSD) Technician.

Your Polaris dealer knows your vehicle best and is interested in your total satisfaction. Be sure to return to your dealership for all of your service needs during, and after, the warranty period.

We also take great pride in our complete line of apparel, parts and accessories, available through our online store at www.purepolaris.com. Have your accessories and clothing delivered right to your door!

POLARIS and POLARIS THE WAY OUT are registered trademarks of Polaris Industries Inc.

Copyright 2009 Polaris Sales Inc. All information contained within this publication is based on the latest product information at the time of publication. Due to constant improvements in the design and quality of production components, some minor discrepancies may result between the actual vehicle and the information presented in this publication. Depictions and/or procedures in this publication are intended for reference use only. No liability can be accepted for omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited.

Printed in U.S.A. 2010 600 Rush Owner's Manual P/N 9922276

TABLE OF CONTENTS

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

This section contains helpful information for owners and drivers and illustrates the location of important identification numbers that should be recorded in the owner's manual.

Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

This section describes safe vehicle operation and identifies warning labels and their locations.

Features . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

This section identifies the locations of your snowmobile's controls and features.

The Perfect Fit . . . . . . . . . . . . . . . . . . . . . . . . . 38

This section includes a Suspension Quick Set-Up Guide and explains how to make additional suspension adjustments for the perfect riding experience.

Pre-Ride Inspections . . . . . . . . . . . . . . . . . . . . 52

This section explains procedures that must be performed before riding.

Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

This section explains proper engine break-in, operation of features and general operating procedures.

Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . 72

This section defines your role, and your dealer's role, in your snowmobile's regular maintenance.

Polaris Products. . . . . . . . . . . . . . . . . . . . . . . 110

Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . .111

Warranty . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 116

Maintenance Log . . . . . . . . . . . . . . . . . . . . . . 125

Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 128

INTRODUCTION

Important Notes for Owners and Drivers

After reading this manual, store it in the snowmobile for convenient reference. It should remain with the snowmobile when the snowmobile is sold.

Some of the illustrations and photos used in this manual are general representations. Your model may differ.

Follow the maintenance program outlined in this manual. Preventive maintenance ensures that critical components of the snowmobile are inspected by your dealer at specific mileage intervals.

You and your dealer must complete the registration form included with your snowmobile and forward it to us. This completed form is necessary to ensure warranty coverage.

Protect and preserve your right to ride by joining your local trail riding clubs.

When teaching inexperienced operators to ride, set up a predetermined course for practice. Make sure they know how to drive and control the snowmobile before allowing them to make longer trips. Teach them proper snowmobile courtesy, and enroll them in driver’s training and safety courses sponsored by local or state organizations.

INTRODUCTION

Preservation of the Environment

Polaris is committed to supporting an environmental education campaign. We encourage state and provincial governments across the snowbelt to adopt rigorous safety training programs that encourage protection of our environment, including wildlife and vegetation.

Snowmobile clubs and other organizations are working together to protect our environment. Please support their efforts and operate your snowmobile with consideration for the protection and preservation of our environment.

Noise Level

One of the most publicized issues about snowmobiles is noise. The Society of Automotive Engineers (SAE), the standard-setting body for snowmobile development, recommends that snowmobiles conform to prescribed sound levels.

Polaris snowmobiles are engineered to conform to these SAE standards. Our muffler systems are designed to reduce noise levels and must not be altered or removed. The sound of your snowmobile may not be welcome to non-snowmobilers, so you have a responsibility to operate your snowmobile with concern for others. We do our part by manufacturing quieter machines; we ask your help to further reduce the impact of noise by operating your snowmobile safely and responsibly.

Air Pollution

Polaris engineers continuously investigate ways to reduce emission levels of two-stroke engines. We expect our efforts to lead to the reduction of potential air pollution.

In addition to our technological research, we encourage government agencies, manufacturers, distributors, dealers, ecologists, and other interested parties to work together to develop data on environmental topics.

INTRODUCTION

Vehicle Identification Numbers

Record your snowmobile's identification numbers and key number in the spaces provided. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a Polaris key blank with one of your existing keys, so if both keys are lost, the ignition switch must be replaced.

Vehicle Model Number: ___________________________________________________

Tunnel VIN (

Engine Serial Number (on recoil housing): _____________________________________

)(right side of tunnel): __________________________________________

Key Number: ____________________________________________________________

SAFETY

Operator Safety

The following signal words and symbols appear throughout this manual and on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual.

The safety alert symbol indicates a potential personal injury hazard.

WARNING

A WARNING indicates a hazardous situation which, if not avoided, may result in death or serious injury.

CAUTION

A CAUTION indicates a hazardous situation which, if not avoided, may result in minor or moderate injury.

NOTICE

A NOTICE indicates a situation that may result in property damage.

SAFETY

WARNING

Operator Safety

Follow the recommended maintenance program beginning on page 73 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals.

Driving a snowmobile requires your full attention. DO NOT drink alcohol or use drugs or medications before or while driving or riding as a passenger. They will reduce your alertness and slow your reaction time.

Snowmobiles are capable of traveling at high speeds. Use extra caution to ensure operator safety. Make sure your snowmobile is in excellent operating condition at all times. Always check major and vital safety components before every ride.

All Polaris snowmobiles are designed and tested to provide safe operation when used as directed. Failure of critical machine components may result from operation with any modifications, especially those that increase speed or power. DO NOT MODIFY YOUR MACHINE. The snowmobile may become aerodynamically unstable at speeds higher than those for which it is designed. Loss of control may occur at higher speeds. Modifications may also create a safety hazard and lead to bodily injury.

The warranty on your entire machine is terminated if any equipment has been added, or any modifications have been made, to increase the speed or power of the snowmobile.

SAFETY

STEP

Operator Safety

Stay Clear of Track

Your snowmobile is propelled by a revolving track that must be partially exposed for proper operation. Do not stand on the plastic flap.

WARNING! Serious injuries may result if hands, feet, or clothing become entangled in the track. Be alert when riding, and remain properly seated to stay clear of the track. Never hold the snowmobile up or stand behind it while warming up the track. A loose track or flying debris could cause serious injury or death. We recommend having your dealer perform all track service and alignment procedures.

Stay Clear of Engine

Never attempt adjustments with the engine running. Turn off the ignition, open the side panels or hood, make the adjustment, secure shields and guards, secure the side panels and hood, and then restart the engine to check its operation.

WARNING! Serious injury can occur if fingers or clothing contact the moving parts of an engine. Always stop the engine before attempting adjustments.

Riding Position

Operating a snowmobile requires skill and balance for proper control. Rider positions may vary with experience and the features available on some snowmobiles, but under many conditions, the proper position is to be seated with both feet on the running boards and both hands on the handlebar grips for proper throttle, brake and steering control.

WARNING! Improper riding position may reduce control and could result in serious injury or death. Always ride in a position that allows for control of your vehicle.

SAFETY

051039

0006.31

Operator Safety

Riding Apparel

Helmet

Wearing a helmet can prevent a severe head injury. Whenever riding a Polaris vehicle, always wear a helmet that meets or exceeds established safety standards.

Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.

Approved helmets in Europe, Asia and Oceania bear the ECE 22.05 label. The ECE mark consists of a circle surrounding the letter E, followed by the distinguishing number of the country which has granted approval. The approval number and serial number will also be displayed on the label.

Eye Protection

Do not depend on eyeglasses or sunglasses for eye protection. Whenever riding a Polaris vehicle, always wear shatterproof goggles or use a shatterproof helmet face shield. Polaris recommends wearing approved Personal Protective Equipment (PPE) bearing markings such as VESC 8, V-8, Z87.1, or CE. Make sure protective eye wear is kept clean.

Clothing

Be prepared, be warm and be comfortable when riding. Be aware of the weather forecast, especially the windchill, and dress accordingly. See the chart on page 20.

WARNING! Avoid wearing loose clothing or long scarves, which can become entangled in moving parts and cause serious injury. Always wear an approved helmet and eye protection.

SAFETY

Operator Safety

Disabled Operators

Safe operation of this rider-active vehicle requires good judgement and physical skills. Operators with cognitive or physical disabilities have an increased risk of loss of control, which could result in serious injury or death.

Survival Preparation

For your safety, always ride in a group of other snowmobilers. Always tell someone where you're going and how long you expect to be gone. If it isn't possible to ride with others, and you must travel into remote areas, always carry survival equipment that's appropriate to the conditions you may encounter. Such equipment may include, but is not limited to: extra clothing, a sleeping bag, a flashlight, food and water, a signaling mirror, a means of building a fire, and a two-way radio or cellular telephone.

Always carry the owner’s manual on your snowmobile. For added protection, purchase and carry the following items on your snowmobile as well:

• Spare Drive Belt • Winter Survival Kit

• Extra Set of Spark Plugs • Trail Map

•Tow Rope •First Aid Kit

• Extra Oil • Tool Kit

• Fuel Deicer

SAFETY

Operator Safety

Rider Capacity

This snowmobile is designed for a single rider only. Never carry a passenger on this snowmobile.

Excessive Speed

WARNING! High speed driving, especially at night, could result in serious injury

or death. Always reduce speed when driving at night or in inclement weather.

Always observe all state and local laws governing snowmobile operation and speed limits. Always be alert and pay attention to the trail ahead. If your speed is 40 MPH (64 km/h), your snowmobile is traveling about 60 feet (18 m) per second. If you look back for only two seconds, your snowmobile will travel about 120 feet (36 m). If your speed is 60 MPH (96 km/h), your snowmobile will travel about 180 feet (55 m) in two seconds.

Traveling at night requires extra caution. Check headlight and taillight to ensure proper operation, and don’t over-drive your headlight beam. Always be able to bring your snowmobile to a stop in the distance illuminated by the headlight.

SAFETY

Operator Safety

Driver Awareness

Slow down when traveling near poles, posts, or other obstacles. Be especially alert if you're snowmobiling after dark. Always be on the alert for wire fences. Single strands are especially dangerous, since there may be a great distance between posts. Guy wires on utility poles are also difficult to distinguish.

Make sure the way is clear before crossing railroads and other roads and highways. The noise of your snowmobile will drown out the sound of approaching vehicles. Look ahead, behind, and to both sides before turning or crossing railroad tracks or highways. Steep embankments may also hide your view. Always leave yourself a way out.

Variances in snow depth and/or water currents may result in uneven ice thickness. You may drown if you break through the ice. Avoid travelling on frozen bodies of water.

SAFETY

Operator Safety

Avalanches

Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain:

• Take an avalanche class

• Travel with experienced people

• Travel on designated trails

• Make sure each person is equipped with a shovel, probe and avalanche beacon.

You don't have to be snowmobiling on a slope for an avalanche to occur. Be aware that all of the snow is connected. You may be riding on a flat slope or snow covered road, but if the snowpack above is unstable enough you can trigger an avalanche on a steeper slope above you. Always be aware of snow conditions above you as you travel in mountainous terrain.

Before riding in mountainous terrain, call or log on to your local avalanche advisory to get current weather and snow stability information.

For more information about avalanche training and avalanche conditions, contact local law enforcement in your area, or visit the American and Canadian online avalanche centers at www.avalanche.org.

SAFETY

Operator Safety

Ice and Snow Build-up

WARNING! Ice and snow build-up may interfere with the steering of your

snowmobile, resulting in serious injury or death. Keep the underhood area free of snow and ice.

Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty is encountered, remove ice and snow build-up that may be obstructing the steering linkage.

Driving on Slippery Surfaces

WARNING! Never attempt an abrupt change of direction when operating on

slippery surfaces. Proceed slowly and use extra caution. Driving on ice or hardpacked snow reduces steering and braking control, which may result in loss of control and serious injury or death. Slow down and use extra caution when operating on slippery surfaces.

Inadequate Snow Conditions

Since snow provides the only lubrication for the power slide suspension and, on liquid cooled models, cooling for the engine, adequate snow cover is a requirement for operation of your snowmobile.

NOTICE: Driving in too little snow will result in excessive wear and damage to

WARNING! Inadequate cooling and lubrication will lead to overheating of the

slide rail and track, causing premature wear, damage and failure, which can result in serious injury. Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces. Avoid operating for prolonged periods on ice, hard-packed surfaces or roads.

the slide rail, track and/or engine.

Operating in Deep Snow

If the snowmobile becomes stuck in snow, clear the running board area of snow, then step down the snow in front of the snowmobile so that when the throttle is opened, the snowmobile will be able to climb up and over the snow.

SAFETY

Operator Safety

Driving Downhill

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

WARNING! When driving on long downhill stretches, pump the brakes. Riding the brakes may cause the brake system to overheat, which may result in brake failure. Excessive or repetitive use of the brakes for high speed stops will also cause an overheated brake system. This condition may lead to a sudden loss of brakes and/or fire and may result in serious injury or death.

Driving in Hilly Terrain

WARNING! Climbing a hill or crossing the face of a slope may result in loss of

balance and snowmobile rollover, causing serious injury or death. Use caution and good judgement when driving in hilly terrain.

Use extra caution when operating in hilly terrain. If climbing a hill is unavoidable, keep your weight low and forward. If you must cross the face of a slope, keep your weight on the uphill side of the snowmobile to maintain proper balance and avoid possible roll-over.

Slow down when reaching the crest of a hill. Be prepared to react to obstacles, sharp drops or other people or vehicles that may be on the other side of the hill.

If you're unable to continue up a hill, turn the snowmobile downhill before it loses momentum. If this isn't possible, spin the track just enough to dig in to prevent it from rolling back down the hill. Stop the engine and set the parking brake (if equipped). Keeping away from the downhill side of the snowmobile, pull the rear of the snowmobile around and point the front end and skis downhill. Remount the snowmobile, restart the engine, release the parking brake, and descend the hill carefully.

SAFETY

Operator Safety

Drive Belt

Do not operate the engine with the drive belt removed.

Any servicing that requires operation without a belt must be performed by your dealer.

NOTICE: Operation of the engine with the belt removed may result in injury or

Intake Silencer

Do not operate the engine with the intake silencer or filter removed.

NOTICE: Damage to the engine may occur if the intake silencer or filter are

Clutches

Do not attempt to service the clutches.

All clutch service must be performed by your dealer. The clutch is a complex mechanism that rotates at high speeds. Each clutch is dynamically balanced before installation. Any tampering may disrupt this precision balancing and create an unstable condition.

Cold Weather Drive-Away

Whenever your snowmobile has been parked for a length of time, especially overnight, always make sure the skis and track are loosened from ice and snow before attempting to drive. Apply the throttle with enough authority to put the snowmobile into motion, but always operate within safety limits.

damage to the engine.

removed.

Maneuverability

While much control and maneuverability is achieved through the steering system and skis, maximum control is achieved by the shifting of your body weight. Maneuverability will change for lighter operators or snowmobiles designed to carry a load.

SAFETY

Operator Safety

Driving Responsibly

Every snowmobile handles differently, and even the most docile conditions may become dangerous if operators drive improperly. If you're new to snowmobiling, acquaint yourself with the snowmobile and with what it will and won't do under various conditions. Even seasoned drivers should spend some time getting the feel for a snowmobile before attempting ambitious maneuvers.

• A snowmobile depends on the rider's body position for proper balance in executing turns, traversing hills, etc. Always start on a smooth, level area to begin building your operating experience.

• Before allowing someone else to use your snowmobile, know the extent of their operating skills. Check to see if they've taken a snowmobile safety course and have an operator's certificate. For their protection, as well as yours, make sure they take a snowmobile safety course. Everyone can benefit from the course.

• Don't "jump" your snowmobile over large drifts or similar terrain. Jumping may injure your back because of spinal compression that could occur when the snowmobile impacts the ground. The seat and suspension of your snowmobile have been designed to provide protection under normal riding conditions. Your snowmobile is not intended for this kind of use.

• Be courteous to oncoming traffic by dimming your headlights and reducing your speed.

• When traveling in a group of snowmobiles, don't tailgate (follow too closely). Leave enough distance between snowmobiles to provide ample stopping room and to provide protection from flying snow and debris. Allow even more distance when driving on slippery surfaces or when driving in darkness or other low visibility conditions. Be aware of any snowmobile traffic around your vehicle. Drive defensively to avoid accidents.

• Remove the key from the ignition when you leave the snowmobile unattended.

SAFETY

Operator Safety

Windchill/Temperature Charts

The following information is provided to help you determine when temperatures become dangerous for riding.

WINDCHILL CHART (_F)

Wind

Speed

40 35 30 25 20 15 10 5 0 -5 -10 -15 -20 -25 -30 -35 -40 -45

MPH

Calm 40 35 30 25 20 15 10 5 0 -5 -10 -15

5 3631251913 7 1 -5-11-16

10 34 27 21 15 9 3 -4 -10 -16

15 32 25 19 13 6 0 -7 -13

20 30 24 17 11 4 -2 -9 -15

25 29 23 16 9 3 -4 -11 -17

30 28 22 15 8 1 -5 -12

35 28 21 14 7 0 -7 -14

40 27 20 13 6 -1 -8 -15

45 26 19 12 5 -2 -9 -16

50 26 19 12 4 -3 -10 -17

55 25 18 11 4 -3 -11

60 25 17 10 3 -4 -11

Frostbite in >>

Actual Thermometer Reading (_F)

Equivalent Temperature (_F)

-20 -25 -30 -35 -40 -45

-22 -28 -34 -40 -46 -52 -57 -63

-22 -28 -35 -41 -47 -53 -59 -66 -72

-19 -26 -32 -39 -45 -51 -58 -64 -71 -77

-22 -29 -35 -42 -48 -55 -61 -68 -74 -81

-24 -31 -37 -44 -51 -58 -64 -71 -78 -84

-19 -26 -33 -39 -46 -53 -60 -67 -73 -80 -87

-21 -27 -34 -41 -48 -55 -62 -69 -76 -82 -89

-22 -29 -36 -43 -50 -57 -64 -71 -78 -84 -91

-23 -30 -37 -44 -51 -58 -65 -72 -79 -86 -93

-24 -31 -38 -45 -52 -60 -67 -74 -81 -88 -95

-18 -25 -32 -39 -46 -54 -61 -68 -75 -82 -89 -97

-19 -26 -33 -40 -48 -55 -62 -69 -76 -84 -91 -98

30 min. 10 min. 5 min.

WINDCHILL CHART (_C)

Wind

Speed

5 2 -1 -4 -7 -10 -13 -16 -19 -22 -25 -28 -31 -34 -37 -40 -43 -46

KPH

Calm 5 2 -1 -4 -7 -10 -13 -16 -19 -22 -25 -28 -31 -34 -37 -40 -43 -46

8 3 0 -4 -7 -11 -14 -18 -22 -25 -29

16 2 -2 -6 -10 -13 -17 -21 -24 -28

24 1 -3 -7 -11 -15 -19 -22 -26

32 0 -4 -8 -12 -16 -20 -24 -28

40 -1 -5 -9 -13 -17 -21 -25 -29

48 -1 -5 -9 -13 -18 -22 -26

56 -2 -6 -10 -14 -18 -22 -26

64 -2 -6 -10 -15 -19 -23 -27

72 -2 -7 -11 -15 -19 -23 -28

80 -3 -7 -11 -15 -20 -24 -28

88 -3 -7 -12 -16 -20 -24

96 -3 -8 -12 -16 -21 -25

Frostbite in >>

Actual Thermometer Reading (_C)

Equivalent Temperature (_C)

-32 -36 -39 -43 -46 -50 -53 -57

-32 -36 -39 -43 -47 -50 -54 -58 -62

-30 -34 -38 -42 -45 -49 -53 -57 -61 -65

-32 -36 -39 -43 -47 -51 -55 -59 -63 -67

-33 -37 -41 -45 -49 -53 -57 -61 -65 -69

-30 -34 -38 -42 -46 -50 -54 -58 -62 -66 -70

-31 -35 -39 -43 -47 -51 -55 -59 -64 -68 -72

-31 -35 -40 -44 -48 -52 -56 -61 -65 -69 -73

-32 -36 -40 -45 -49 -53 -57 -61 -66 -70 -74

-33 -37 -41 -45 -50 -54 -58 -62 -67 -71 -75

-29 -33 -37 -42 -46 -50 -55 -59 -63 -67 -72 -76

-29 -34 -38 -42 -47 -51 -55 -60 -64 -68 -73 -77

30 min. 10 min. 5 min.

SAFETY

Safety Labels and Locations

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

If any label becomes illegible or comes off, contact your Polaris dealer to purchase a replacement. Replacement safety labels are provided by Polaris at no charge. The part number is printed on the label.

Clutch Warning

This warning label is found on the oil bottle:

WARNING Do not operate engine with hood or side panels open. Do not attempt adjustment with engine running. Do not operate engine with the clutch guard removed. Never run engine with drive belt removed. Never service clutches yourself. See your dealer.

Pressure Cap Warning

This warning label is found on the pressure cap of applicable liquid cooled models:

WARNING Do not open hot. Test or replace when changing coolant. Press

down and turn to release cap. 13 PSI

SAFETY

Track Warning

Reverse Warning

“No Passenger”

Warning

Safety Labels and Locations

Track Warning

The track warning label is at the rear of the snowmobile:

WARNING Stay clear of track. Do not sit on

seat back. Entanglement with the track or a fall from seat back may result in severe injury or death.

“No Passenger” Warning

Snowmobiles designed for a single rider only have the NO PASSENGER warning label on the lower left side of the console:

WARNING This vehicle is designed for operator

only. NO PASSENGER

Reverse Warning

The reverse warning label is located on the console, either beside the steering post or below the windshield:

WARNING Reverse operation, even at low

speeds, can cause loss of control resulting in serious injury or death. To avoid loss of control, always:

• Look behind before and while backing up.

• Avoid sharp turns.

• Shift to or from reverse only when stopped.

• Apply throttle slowly. NOTE: For more information, see Owner's Manual. If electric reverse:

• Machine stopped and engine at idle, push yellow button on LH control to reverse. Flashing light on dash indicates reverse operation.

• Push button again to return to forward.

SAFETY

Operation

Warning

Safety Labels and Locations

Operation Warning

The operation warning label is also located on the console.

• To avoid serious injury or death, read and understand all warnings and the Owner's Manual before operation. If manual is missing, contact a Polaris dealer for a replacement.

• This vehicle is capable of high speeds. Buried objects or uneven terrain can cause loss of control. Reduce speed and use extreme caution when operating in unfamiliar terrain.

• Excessive speed, especially at night or with limited visibility, can result in insufficient time for you to react to terrain changes, to avoid unexpected obstacles, or to stop safely.

• Never consume alcohol or drugs before or while operating this vehicle.

• In an emergency, push down the Auxiliary Shut-Off Switch, located on the top of the throttle control assembly, to stop the engine. Then pull the brake lever to stop.

• Always wear an approved helmet, eye protection, and adequate clothing while operating this vehicle.

• This vehicle is designed for adult use only. Check local laws for age requirements.

• When operating with a passenger (on approved models only) reduce speed and allow extra space for steering and stopping. A passenger reduces your ability to control the vehicle.

• When operating on hard-packed snow, ice, or when crossing roads, steering and braking ability are greatly reduced. Reduce speed and allow extra space to turn or stop.

• To maintain vehicle control on ice or hard-packed surfaces, you should have a proper balance of ski carbides to track studs. See Owner's Manual for proper use of traction products.

• Repeated stops from high speed may cause fading or sudden loss of braking ability.

• Parking brake may relax when used for long periods. Do not leave brake engaged for more than five minutes.

• Before starting engine, check throttle, brake, and steering for proper operation. Make sure hood and side panels are latched. Be seated and in position to control the vehicle.

Oil injection system: Use unmixed fuel only. Check oil level when refueling.

FEATURES

1. Nosepan

2. Skis

3. Front Bumper

4. Hood

5. Headlight

6. Windshield (accessory)

7. Handlebar

8. Operator Seat

9. Taillight

10. Rear Bumper

11. Snow Fl a p

12. Suspension

13. Track

14. Side Panel

15. Side Panel Fasteners

1. Fuel Filler Cap

89 10

2. Brake Lever

3. MFD Gauge

4. Ignition Switch

5. Engine Stop Switch

6. Throttle Control

7. Recoil Starter Handle

8. Parking Brake Lock

9. Handlebar Grip Warmer Switch

10. Thumbwarmer Switch

11. Electronic Reverse Button

12. Mode Switch

13. Headlight Dimmer Switch

FEATURES

Right

Compartment

(Storage)

Left

Compartment

(Tool Kit)

Fastener

Straps

Belt

Removal

To ol

Spare Plugs

Fuel Resistor

Spark Plug

Wrench

Spare Wrench

Foam Tool

Holder

Suspension

Gauge

Down

Storage Bag/Tool Kit

A storage bag is located under the seat. The left portion of the bag is designed to store the tool kit. The tool kit includes tools and a foam tool holder. The right side of the bag can be used to stow other items.

Adjustable Headlights

Move the headlight adjuster to the left to adjust the headlight beam upward. Move the adjuster to the right to adjust the beam downward.

FEATURES

Detonation Elimination Technology (DET)

The DET system prevents damage to the engine from detonation by going into an engine protection mode whenever the DET system is active. Depending on the level of detonation encountered, the check engine light could be solid, it could flicker or it could flash steadily.

Check Engine Light Indicates

Off Mild detonation may be detected

Solid or Flickering Excessive detonation detected

Steady Flashing Severe detonation detected, RPM will be limited

When excessive detonation is detected, the check engine light will come on solid, or it may flicker, and you may notice decreased engine performance and RPM when the DET system is activated. In most cases this is temporary and the operator does not need to take any action. The engine will return to its normal performance automatically.

If severe detonation occurs, the check engine light will begin to flash steadily and the gauge indicator will read “dET” (see illustration). The engine will enter a limp home mode and RPM will be limited to 6500 RPM. The engine will remain in this mode until it is shut down and restarted.

The most likely causes of severe detonation are outlined in the troubleshooting table below.

DET Troubleshooting

Cause of DET Activation Solution

Poor quality fuel Replace with higher quality fuel Incorrect ethanol/non-ethanol fuel

resistor installed Low fuel/no fuel in tank Refuel with recommended fuel Water in fuel Replace with recommended fuel Plugged fuel filter See your Polaris dealer for service Alcohol-based fuel additive used with

Ethanol fuel

Improper engine modifications Do not modify the engine

Verify correct fuel resistor for fuel type in tank

Do not add deicers or additives that contain any form of alcohol while using up to 10% ethanol fuel

FEATURES

Rider Information

Center

Check Engine

Indicator

High Beam

Indicator

Low Oil

Indicator

Over-

Temperature

Indicator

Park Brake

Indicator

Reverse Indicator

MODE Button

SELECT

Button

Mode/Set

Switch

Instrument Cluster

The instrument cluster contains indicator lights and the rider information center. The information center can be controlled by either the MODE and SELECT buttons on the instrument cluster or by the MODE/ SET switch on the left handlebar.

NOTICE: Certain products will damage

the lens and other plastic surfaces. Do not use alcohol to clean the instrument cluster. Immediately clean off any gasoline that splashes on the instrument cluster.

FEATURES

Instrument Cluster

Indicators

Check Engine Indicator

This indicator appears if an EFI-related fault occurs. Do not operate the snowmobile if this warning appears. Serious engine damage could result. See your dealer. See page 36 for diagnostic code definitions.

Over-Temperature Indicator

This indicator illuminates to alert the operator that the engine is overheating. The operator should take action to cool the engine. See page 86. If the indicator flashes, continued operation could result in serious engine damage. Stop the engine immediately.

Low Oil Indicator

This indicator appears when engine oil is too low. Immediately stop the engine. Add oil before operating. See page 65.

High Beam Indicator

The high beam indicator illuminates when the lights are set to high beam.

Parking Brake Indicator

This indicator illuminates when the parking brake is engaged. It will also illuminate when the service brake is in use. See page 56.

Reverse Indicator

This indicator flashes when the transmission is in reverse. See page 70.

FEATURES

Instrument Cluster

Rider Information Center

The rider information center is located in the instrument cluster. The center displays vehicle speed, engine speed, odometer, resettable trip meters (2), total engine hours of operation, fuel level, engine temperature and diagnostic display mode.

Setting changes can be made with the engine running or with the engine off. If the engine is off, make sure the stop switch is pressed down, and turn the ignition key to the START position briefly to activate the instrument cluster. The instrument cluster will illuminate for about 90 seconds.

The information center is set to display standard units of measurement for distance and temperature. To change to metric units, see page 34.

FEATURES

Instrument Cluster

Rider Information Center

1. Information Display Area - This area displays either engine speed or vehicle speed (whichever is not displayed in the speed display), engine temperature and maximum vehicle speed. To change the display, see page 32.

2. Speed Display - The speed display area displays either vehicle speed or engine speed. To change the display, see page 32.

3. Fuel Gauge - The segments of the fuel gauge show the level of fuel

in the fuel tank. When the last segment clears, a low fuel warning is activated. All segments including the fuel icon will flash. Refuel immediately.

Tip: If the fuel icon fails to display, an open or short circuit has occurred in the

fuel sensor circuit. See your dealer.

4. Odometer/Engine Hour Display - This area displays the odometer,

Trip A, Trip B and engine hours. To change the display, see page 33.

5. Battery Power - This indicator illuminates when battery power is

low.

6. Playback Icon - The playback function allows the rider to record

and play back engine speed, vehicle speed and throttle position sensor information for up to three minutes. The playback icon flashes while recording. See page 33.

FEATURES

Instrument Cluster

Rider Information Center

Speed Display Area

The speed display area displays either vehicle speed or engine speed. Vehicle speed is displayed in either miles per hour (MPH) or kilometers per hour (km/h). Engine speed is displayed in revolutions per minute (RPM).

1. To change which item displays, first make sure the information display area is set to display either engine speed or vehicle speed.

2. Press and hold the mode button (on the instrument cluster) or the mode switch (on the left handlebar) for three seconds.

Information Display Area

This area displays either engine speed or vehicle speed (whichever is not displayed in the speed display), engine temperature and maximum vehicle speed. To change the display, press and release the MODE button or the MODE switch until the desired item is displayed.

FEATURES

Instrument Cluster

Rider Information Center

Odometer/Engine Hour Display Area

This area displays the odometer, Trip A meter, Trip B meter and engine hours meter.

The odometer displays the total distance traveled by the vehicle since manufacture. Each trip meter records the distance traveled by the vehicle on a trip if the meter is reset before each trip. The engine hour meter displays the total hours the engine has been in operation since manufacture.

To change the display, press and release the SELECT button or the SET switch until the desired item is displayed.

To reset a trip meter, press and hold the SELECT button or the SET switch until the meter resets to zero.

Playback Function

The playback function allows the rider to record and play back engine speed, vehicle speed and throttle position sensor information for up to three minutes.

1. To begin recording, simultaneously press and hold the MODE and SELECT buttons on the instrument cluster for three seconds. The playback indicator will flash while the instrument cluster is recording.

2. To play back the recorded data, stop the vehicle and wait for engine speed to drop below clutch engagement.

3. Simultaneously press and release the MODE and SELECT buttons on the instrument cluster.

4. Applying the throttle will clear the display and return the instrument cluster to normal operation.

FEATURES

Instrument Cluster

Rider Information Center

Standard/Metric Display

The odometer and temperature displays can be viewed in either standard or metric units of measurement. Both displays change if units are changed. The new settings will remain until changed by the operator.

Change Method 1

1. Press and release the MODE button or MODE switch until engine temperature displays.

2. Press and hold the MODE button or MODE switch until the units

change.

Change Method 2

1. Press and release the SELECT button or SET switch until the odometer displays.

2. Press and hold the SELECT button or SET switch until the units

change.

FEATURES

Instrument Cluster

Rider Information Center

Diagnostic Display Mode

The diagnostic display mode is for informational purposes only. Please see your Polaris dealer for all major repairs.

The diagnostic mode is accessible only when the check engine warning indicator is illuminated and a diagnostic code is active.

Do not stop the engine if you want to view the active code (failure code). Active codes cannot be retrieved if power is interrupted to the instrument cluster. The codes will become inactive codes if power is interrupted. Inactive codes are stored in the history of the unit. Please see your Polaris dealer to retrieve inactive codes.

Use the following procedure to view active codes.

1. Do not stop the engine.

2. Press and release the SELECT button or SET switch to toggle to the diagnostic display mode. When a code is active, the diagnostic display mode will appear immediately following the engine hour display.

TIP: When the diagnostic mode is displayed, the check engine warning indicator

will begin to flash.

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 indicates the fault mode, such as open or short circuit.

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 are retrieved.

5. See page 36 for code definitions and failure descriptions.

FEATURES

Instrument Cluster

Rider Information Center

Diagnostic Display Code Definitions

Open Load:

the chart (injector, fuel pump, etc.), or the item has failed.

Short-to-Ground:

control unit and the item listed in the chart.

Shorted Load:

shorted together, or the item has shorted internally.

Short-to-Battery:

the electronic control unit is shorted to a wire at battery voltage.

Throttle Position Sensor

Engine Temperature Sensor

Intake Air Temperature Sensor Voltage Too High 105 3

Barometric Pressure Sensor

Exhaust Temperature Sensor Voltage Too High 173 3

Crankshaft Position Sensor Circuit Fault 636 8

Knock Sensor 1 Voltage Too Low 731 4 Vehicle Speed Sensor Vehicle Speed Too High 84 0

Injector 1 (MAG) (SDI Part Load)

Injector 2 (PTO) (SDI Part Load) Driver Circuit Open/Grounded 652 5

There is a break in the wires that lead to the item listed in

The wire is shorted to ground between the electronic

The wires leading to the item listed in the chart are

The wire leading from the item listed in the chart to

Diagnostic Codes

Component Condition SPN FMI

Voltage Too High 51 3 Voltage Too Low 4 Abnormal Rate of Change 10 Voltage Too High 110 3 Voltage Too Low 4 Temperature Too High 16 Engine Overheat Shutdown 0 Temperature Above Normal Range 15

Voltage Too Low 4 Voltage Too High 108 3 Voltage Too Low 4

Voltage Too Low 4

Plausibility Fault 2

Vehicle Speed Too Low 1 Data Erratic, Intermittent or Missing 2 Driver Circuit Open/Grounded 651 5 Driver Circuit Short to B+ 3

Driver Circuit Short to B+ 3

FEATURES

Instrument Cluster

Rider Information Center

Diagnostic Display Code Definitions

Diagnostic Codes

Component Condition SPN FMI

Ignition Coil Primary Driver 1 (MAG) Driver Circuit Open/Grounded 1268 5 Fuel Pump Driver Circuit

Chassis Relay Driver Circuit Open/Grounded 520208 5

Exhaust Valve Solenoid Driver Circuit Grounded 520215 5

ECU Memory Checksum/CRC Error 628 13 Alternator Power Supply Potential

(DC-SDI DC Chassis Voltage) (Fuel Pump Power)

Sensor Supply Voltage 1 (DC-SDI TPS/TMAP PWR)

Sensor Supply Voltage 2 (DC-SDI Ground Speed Sensor PWR)

ECU Output Supply Voltage 2 (DCSDI Injection Supply PWR)

Throttle Release Signal Voltage Too High 520194 3

Knock Level Cylinder 1 (MAG) Knock Above Critical Level 1352 0 Knock Level Cylinder 2 (PTO) Knock Above Critical Level 1353 0 Fuel Type Selected Voltage Too High 524007 3

Driver Circuit Open/Grounded 1347 5

Driver Circuit Short to B+ 3

Voltage Too High 167 3 Voltage Too Low 4

Voltage Too High 3509 3 Voltage Too Low 4 Voltage Above Critical Level 0 Voltage Below Critical Level 1 Voltage Too High 3510 3 Voltage Too Low 4 Voltage Above Critical Level 0 Voltage Below Critical Level 1 Voltage Too High 3598 3 Voltage Too Low 4 Voltage Above Critical Level 0 Voltage Above Warning Level 16 Voltage Below Critical Level 1 Voltage Below Warning Level 18

Voltage Too Low 4 Signal Out Of Range 2 Throttle Stuck 7

Voltage Too Low 4 Signal Out Of Range 2

THE PERFECT FIT

Spring Retainer

Silver/Red Junction

Suspension Quick Set-Up Guide

The suspension on your RUSH is incredibly easy to adjust to your weight and riding style. Just remember three simple steps:

1. Set up rear shock spring preload for rider weight.

2. Adjust the rear spring to tune vehicle balance (ski pressure and weight transfer).

3. Adjust shock clickers to tune ride quality (stiffer or softer ride).

The following Quick Set-Up Guide walks you through what you need to know to get started, and additional detail is available on the pages immediately following the guide. See pages 40-41 for factory and initial suspension charts for the standard spring as well as for accessory springs that are available for heavier or lighter riders.

Step 1: Set up rear shock spring preload for rider weight.

Before riding for the first time, use the gauge supplied with your snowmobile to adjust rear spring preload to the appropriate setting for the rider’s weight.

Position the narrow end of the gauge flush with the spring retainer. Turn the spring until the rider’s weight setting aligns with the silver/red junction on the shock body.

Make no other suspension adjustments at this time. Test ride the snowmobile in various terrain to fully experience the existing suspension settings before making adjustments.

TIP: Initially, heavier riders may want to set the shock clickers 2-4 clicks higher

than lighter riders.

THE PERFECT FIT

Suspension Quick Set-Up Guide

Step 2: Adjust the rear spring to tune vehicle balance.

After the initial test ride, make adjustments to the rear shock spring to improve vehicle balance. Increasing preload will increase ski pressure and result in less weight transfer for flatter cornering and more precise steering response. Decreasing preload will decrease ski pressure and result in more weight transfer, or less weight on the skis when accelerating.

Ride Experience Adjustment

Too much weight transfer

•Ski pressure is too light

•Skis push

Too little weight transfer

•Ski pressure is too heavy

•Steering is heavy

Turn rear shock spring retainer clockwise

Turn rear shock spring retainer counter-clockwise

See

Page

Step 3: Adjust shock clickers for ride quality.

After making spring adjustments, adjust shock clickers to control bottoming. Turning a clicker clockwise increases damping for a stiffer ride and less bottoming. Turning a clicker counter-clockwise decreases damping for a softer ride.

Test ride the snowmobile and continue making spring and clicker adjustments until you achieve the perfect ride.

Ride Experience

Bottoming in the IFS IFS shock - after

Bottoming in the center Front track shock Clockwise 46

Bottoming in the rear Rear shock Clockwise 47

No bottoming, but ride is harsh in front or rear

Harsh in chatter/bumps Rear shock Counter-clockwise 47

Clicker

to Adjust

150 mi. (240 km) break-in

Rear shock Counter-clockwise 47

Adjustment

Clockwise 44

See

Page

THE PERFECT FIT

Suspension Quick Set-Up Guide

Accessory rear shock springs are available for riders of different weights. A corresponding gauge is available for each spring type.

The gauge provided with your snowmobile is calibrated for the stock 190 spring, which should be used by most riders. Do not change springs unless your weight is at the very high or very low end of the 190 stock spring rider weight range and adjustments to the factory-installed spring have not perfected your ride.

In the following spring guide, the dimension is as measured from the spring retainer to the silver/red junction on the shock body. See page 38.

Spring Guide

Accessory

Stock

190 Spring

Rider

Weight Dimension

lbs.

kg in. cm lbs. kg in. cm lbs. kg in. cm

120

54 2 5/8

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

190

86 3 1/2 8.9 125 57 3 1/2 8.9 335 152 3 1/4

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 - ---

240

109 4 1/8 10.5 155 70 4 1/8

250

113 4 1/4

6.7 90 41 2 5/8 6.7 240 109 2 3/8 6.0

Min

10.8 - -------

Max

120 Spring

See your Polaris dealer to order an accessory

spring and the gauge calibrated for that spring.

Rider

Weight Dimension

10.5 - -- -

Max

Accessory 260 Spring

Rider

Weight Dimension

8.3

Max

THE PERFECT FIT

Suspension Quick Set-Up Guide

Factory Suspension Settings

IFS and Front Track Shock

IFS Shock Clicker 6 clicks clockwise from full soft

IFS Shock Spring Preload 3 3/4" (9.5 cm) from body end to retainer

Front Track Shock Clicker 2 clicks clockwise from full soft

Front Track Shock Spring Preload 1 1/4" (3.2 cm) from body end to retainer

Stock 190 Rear Spring

Rear Shock Clicker 4 clicks clockwise from full soft

Rear Shock Spring Preload See Optional Spring Guide (page 40)

Accessory Spring Recommended Initial Settings

Accessory 120 Rear Spring

Rear Shock Clicker 4 clicks clockwise from full soft

Rear Shock Spring Preload See Optional Spring Guide (page 40)

Accessory 260 Rear Spring

Rear Shock Clicker 4 clicks clockwise from full soft

Rear Shock Spring Preload See Optional Spring Guide (page 40)

Polaris recommends that riders use this Quick Set-Up Guide to make any adjustments for rider weight and trail conditions. If additional tuning is needed after you have exhausted all possible adjustments to the rear shock spring and clicker, refer to the information on the following pages of this manual.

THE PERFECT FIT

Front Suspension Adjustments

Independent Front Suspension (IFS)

Factory settings, combined with user adjustments to the rear shock spring, should be all that’s necessary to provide the best riding experience for most riders. If all rear shock spring adjustments have been exhausted and rider weight is at the very high or very low weight range for the stock spring, additional adjustments are possible to the IFS.

Settings will vary from rider to rider, depending on rider weight, vehicle speed, riding style, and trail conditions. We recommend starting with factory settings and then customizing each adjustment individually to suit rider preference. The snowmobile should be methodically tested, one change at a time, under the same conditions (trail and snow conditions, vehicle speed, riding position, etc.) after each adjustment until the best ride is achieved.

Break in the suspension for about 150 miles (240 km) before making adjustments to the front suspension.

IFS Components

1. Skis

2. Front shocks and springs

3. Rod ends

4. A-arms

IFS Adjustment Options

• Front shock spring preload

• Compression damping

• Optional springs

• Optional shock valving

THE PERFECT FIT

Front Suspension Adjustments

IFS Shock Spring Preload

Increasing spring preload will increase ski-to-ground pressure. Decreasing spring preload will decrease ski-to-ground pressure. When adjusting, be sure the springs on both the left and right sides of the machine are at the same adjustment.

The initial IFS preload setting is 3 3/4 inches (9.5 cm) from body end to retainer. To change shock spring preload, grasp the spring retainer and rotate it.

Increasing the spring preload too much may adversely affect the handling of the snowmobile and the performance of the suspension. Never exceed one inch (2.54 cm) of preload beyond the factory settings.

When decreasing preload, make sure at least two turns of preload are holding the spring between the retainer on the top of the shock and the threaded spring preload adjuster nut on the shock body. Failure to do so could cause the retainer to fall off when the suspension is fully extended.

TIP: Other spring options are available. Please

see your Polaris dealer.

THE PERFECT FIT

Softer

Ride

Stiffer

Ride

Front Suspension Adjustments

IFS Shock Compression Damping

Make adjustments to the shock clickers to control bottoming. Make the adjustments in 1-to-2-click increments, then test ride. Repeat the adjustment until the desired result is achieved.

TIP: Initially, heavier riders may want to set the shock clickers 2-4 clicks higher

than lighter riders.

The standard clicker setting is 6 clicks from the softest position.

• Turn the clicker clockwise for a

stiffer ride (as viewed from the top).

• Turn the clicker counter-clockwise

for a softer ride.

When adjusting, we recommend that you turn the clicker only one or two clicks, then test ride. Always adjust both shocks equally.

Shock Valving

Some shocks can be revalved if spring preload alone isn't sufficient and further adjustment is desired to control suspension stiffness. Please see your Polaris dealer.

WARNING! Changing shock valving requires special tools and a sound knowledge of mechanical theory, tool use, and shop procedures to perform the work safely and correctly. Shocks contain high-pressure nitrogen gas. Use extreme caution when handling high-pressure service equipment. We recommend that this work be performed by a Polaris dealer.

THE PERFECT FIT

Rear Suspension Adjustments

Rider weight, riding style, trail conditions, and vehicle speed all affect suspension action.

Each rear suspension can be adjusted to suit rider preference and deliver excellent performance for a given set of conditions. However, all suspension designs and adjustments involve a compromise, or trade-off. For example, a suspension set up for snowcross racing would provide a very stiff ride on the trail. A suspension set up for trail riding would bottom out harshly on a snowcross course.

Additional adjustments should be made after initial setup. Make adjustments to one area at a time so you can evaluate the change. For further assistance, see your dealer.

Suspension Performance Tips

• Rider weight usually determines the position at which the spring preload should be set. However, this may vary with riding style. With a little experimentation, each rider can find a preferred set-up.

• In deep snow, a new rail slide will offer improved performance over worn rail slide. It can also improve top speed.

• When riding on ice or hard-packed snow, adding a set of bogie wheels to the rail may enhance the snowmobile's performance. Bogie wheel kits are available from your dealer.

Track Tension

Track adjustment is critical for proper handling. Always maintain correct tension and alignment. Refer to the track tension maintenance section beginning on page 100.

THE PERFECT FIT

Stiffer Softer

Rear Suspension Adjustments

Front Track Shock Compression Damping

Make adjustments to the shock clicker to control bottoming. Make the adjustments in 2-click increments, then test ride. Repeat the adjustment until the desired result is achieved.

TIP: Initially, heavier riders may want to

set the shock clickers 2-4 clicks higher than lighter riders.

The standard clicker setting is 2 clicks from the softest position.

• Turn the clicker clockwise for a stiffer ride.

• Turn the clicker counter-clockwise for a softer ride.

Front Track Shock Spring Preload

Increasing spring preload will decrease ski-to-ground pressure. Decreasing spring preload will increase ski-toground pressure.

The initial preload setting is 1 1/4 inches (3.2 cm) from body end to retainer. To change shock spring preload, grasp the spring retainer and rotate it.

Increasing the spring preload too much may adversely affect the handling of the snowmobile and the performance of the suspension.

TIP: Other spring options are available. Please see your Polaris dealer.

THE PERFECT FIT

Stiffer Softer

Rear Suspension Adjustments

Rear Shock Spring Preload Settings

Make adjustments to the rear shock spring to tune vehicle balance. Increasing preload will increase ski pressure and result in less weight transfer and flatter cornering and more precise steering response. Decreasing preload will decrease ski pressure and result in more weight transfer, or less weight on the skis when accelerating.

Turn the spring retainer up to one turn from the initial setting, then test ride. Repeat the adjustment in one-turn increments until the desired result is achieved.

Increasing the spring preload too much may adversely affect the handling of the snowmobile and the performance of the suspension.

Rear Shock Clicker

Make adjustments to the shock clicker to control bottoming, chatter and general riding comfort. Make the adjustments in 2-click increments, then test ride. Repeat the adjustment until the desired result is achieved.

TIP: Initially, heavier riders may want to set

the shock clickers 2-4 clicks higher than lighter riders.

The standard clicker setting is 4 clicks from the softest position.

• Turn the clicker clockwise for a

stiffer ride.

• Turn the clicker counter-clockwise

for a softer ride.

THE PERFECT FIT

Loosen top bolts to adjust handlebar angle

Loosen bottom bolts to adjust handlebar position

Handlebar Adjustments

Handlebar Position

1. Loosen the four bolts on the

bottom of the adjuster block. If necessary, pry the blocks apart with a screwdriver.

2. Adjust the handlebar forward

or rearward to the desired position.

3. Tighten the bolts.

Handlebar Angle

1. Loosen the four bolts on the

top of the adjuster block. If necessary, pry the blocks apart with a screwdriver.

2. Adjust the handlebar forward

or rearward to the desired angle.

3. Tighten the bolts.

THE PERFECT FIT

Accessories

Polaris offers a wide range of accessories for your snowmobile to help make each ride more enjoyable.

Use only Polaris parts and accessories on your Polaris snowmobile. Use of unapproved parts and accessories may result in:

• Non-compliance with government/industry requirements

• Voiding of warranty

• Injury to self or others This applies, but is not limited to the following areas: brakes, clutches,

fuel systems, and exhaust systems. Exhaust systems are critical safety areas that must use approved Polaris parts. Please see your Polaris dealer for service.

THE PERFECT FIT

Traction Products

Studs

Use only Polaris traction products on your snowmobile. Track warranties are void if track damage or failure results from improper or excessive stud installation or the use of non-Polaris traction products.

The longest stud length recommended for your factory-installed track is 1 1/4 inches (31.75 mm). Never exceed the recommended stud length.

See your dealer about installing studs and/or carbides.

NOTICE: Always install wear strips before installing studs. Failure to install wear

Track studding will enhance braking control on hard-packed snow or ice, but extreme caution is still required on such surfaces. Steering ability may be reduced on hard-packed snow or ice.

When studded tracks are used, increased wear to the brake pads will result from increased braking. Extended-wear brake pad kits are available. See your dealer.

NOTICE: Aggressive studding patterns may require grinding protruding stud

Before equipping your snowmobile with traction products, be aware of the laws in your area pertaining to the use of traction products.

strips may result in cooler or tunnel damage. See page 51. Never add shims to the wear strip. Track damage will result because

of lack of clearance between upper carrier wheels and track. Use of studs longer than the recommended length on snowmobiles

equipped with center coolers will result in center cooler damage or damage to the tunnel.

bolts flush to prevent idler wheel damage. Maintain track tension on studded tracks on the tight side of the spec to prevent heat exchanger

damage. The center of the stud must be at least 1 1/8 the outside edge of the track.

I (2.9 cm) from

THE PERFECT FIT

Traction Products

nCarbide Skags

A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain. Use carbide skags with studded tracks to help maintain proper vehicle steering and control. See page 105.

If your snowmobile has carbide skags, it may be necessary to add track studs to maintain proper vehicle control. Maintain a proper balance between the number of studs and the length of carbide on the skags (the more studs you use, the longer the carbide on the skags should be). See your dealer's track studding chart.

Wear Strips

To avoid excessive tunnel wear, tunnel wear strips must be installed whenever track studding is used. Wear strips are designed for a specific stud length.

See your dealer's studding chart for recommended traction accessories.

NOTICE: Whenever wear strips are relocated, be sure there's adequate stud

clearance to the heat exchangers. Lack of clearance may result in damage to heat exchangers.

PRE-RIDE INSPECTIONS

Pre-Ride Checklist

Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined on the referenced pages. Look for a checkmark (n) on the referenced pages to locate the pre-ride inspection items.

Item See Page

Drive Belt Condition 95

Steering System 57

Recoil Rope 57

Coolant Level 85

Chaincase Oil Level 78

Injection Oil Level 65

Parking Brake Lock/Brake Lever/Brake System 55, 56, 90

Auxiliary Shut-Off Switch (Engine Stop Switch) 58

Ignition Switch 58

Headlight/Taillight/Brakelight 58

Suspension Mounting Bolts 53

Skags (Wear Bars) 105

Ski Saddle and Spindle Bolts 53

Hood and Side Panel Fasteners 77

Throttle Lever/Safety Switch 66, 67

Rear Wheel Idler Bolts 101

Tether Switch/Strap (if equipped) 58

Track Alignment/Condition 57, 102

Rail Slide Condition 106

PRE-RIDE INSPECTIONS

Pre-Ride Suspension Inspection

Loose nuts and bolts can reduce your snowmobile's reliability and cause needless repairs and down time. Before beginning any snowmobile trip, a visual inspection will uncover potential problems. Check the following items on a weekly basis or before any long trip.

Item See Page

Check suspension mounting bolts for tightness. --

Check rear idler wheel bolts for tightness. 101

Check rear idler adjusting bolt locknuts for tightness. --

Check front torque arm limiter strap condition. --

Check rail slide condition. 106

Check track tension. 100

Check ski runner/skag condition. 105

Check ski spindle bolts for tightness. --

Check tie rod end nuts for tightness. --

PRE-RIDE INSPECTIONS

Before Starting the Engine

Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never start the engine without checking all vehicle components to be sure of proper operation.

WARNING! Operating the vehicle with worn, damaged, or malfunctioning components could result in serious injury or death. Never start the engine without checking all vehicle components to be sure of proper operation.

Read and Understand Your Owner's Manual

Read the Owner's Manual completely and refer to it often. The manual is your guide to safe and enjoyable snowmobiling experience.

n Throttle Lever

The throttle and brake are the primary controls of your snowmobile. Always make sure both are functioning properly.

Squeeze the throttle lever to make sure it compresses evenly and smoothly. When released, the lever should immediately return to the idle position without binding or hesitation. If the throttle does not function smoothly, or if you discover excessive lever freeplay, DO NOT start the engine. Have the throttle serviced immediately.

n Throttle Safety Switch

Test the throttle safety switch system before the snowmobile is operated. See page 66.

PRE-RIDE INSPECTIONS

1/2I (1.3 cm)

Before Starting the Engine

n Brakes

Always check the following items for proper operation before starting the engine.

Brake Lever Travel

Squeeze the brake lever. It should move no closer to the handgrip than 1/2I (1.3 cm). A smaller distance indicates low brake fluid level or air in the hydraulic system. Refer to the brake bleeding information on page 92 or see your dealer for service.

Lever Feel

If the brake lever feels “spongy” when squeezed, check the brake fluid level and condition. Add fluid as needed. See page 91.

WARNING! Continued use of “spongy” brakes may cause a complete loss of brakes, which could result in serious injury or death. Always have the brakes serviced at the first sign of sponginess.

PRE-RIDE INSPECTIONS

Before Starting the Engine

n Parking Brake Lever Lock

Use the parking brake lever lock only when you want the snowmobile to remain stationary; for example, when parked on an incline for a period of five minutes or less.

1. Brake Lever

2. Parking Brake Lever Lock

3. Master Cylinder Reservoir/

Cover

4. Fluid Level Indicator

Lock Engagement

To engage the lock, squeeze the brake lever tightly and push forward on the lock. Hold the lock forward while releasing the brake lever.

TIP: If the brake lever is squeezed tightly enough, the lock will move freely into

place. Do not force the lock or it may break.

The parking brake light will illuminate if the parking brake lever lock is set while the engine is running. It will also illuminate when the service brake is in use. If the parking brake light does not come on when the parking brake or service brake is in use, have it serviced by your dealer.

Lock Release

To release the lock, squeeze the brake lever tightly. The lock will return to the unlocked position.

WARNING! If the parking brake lever lock is partially or entirely engaged while riding, the brakes may overheat, resulting in brake damage. In extreme cases it could cause a fire, which could result in serious injury or death. Always ensure that the lever lock is completely disengaged before operating the snowmobile.

PRE-RIDE INSPECTIONS

Before Starting the Engine

n Steering System

WARNING! Ice and snow build-up may interfere with the steering of your

snowmobile, resulting in serious injury or death. Keep the underhood area free of snow and ice.

n Track

Track damage or failure caused by operation on ice or poor lubrication conditions voids the track warranty.

WARNING! Operating the snowmobile with a damaged track increases the possibility of track failure, which could cause loss of control resulting in serious injury or death. Always inspect the track for damage before using the vehicle.

WARNING! Use of traction products such as studs increases the possibility of track damage and/or failure. Driving at high speeds for extended periods of time in marginal lubrication could severely damage track rods, break track edges, and cause other track damage. Examples of marginal lubrication would include frozen bodies of water without snow cover, icy trails, and no-snow conditions.

n Hood and Side Panel Fasteners

The hood and side panels of the snowmobile protect the operator from moving parts. Never operate a snowmobile with the hood or side panels open or removed. Always ensure that the hood and side panels are securely in place before starting the engine.

n Seat Latches

If your snowmobile is equipped with a removable seat, ensure that the seat is properly installed and securely latched before each use of the snowmobile.

n Recoil Rope

Inspect the recoil rope and handle for excessive wear, and make sure the knot securing the rope inside the handle is secure. If excessive wear is found, see your Polaris dealer for replacement.

PRE-RIDE INSPECTIONS

Start the Engine and Check

Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never engage the starter when the engine is running. Never start the engine without checking all vehicle components to be sure of proper operation. See Before Starting the Engine beginning on page 54.

n Engine Stop Switch

Check the auxiliary shut-off switch for proper operation. Push the switch down to stop the engine. Pull it up to allow restarting.

n Ignition Switch

Make sure the engine stops when the ignition switch is turned to OFF.

n Tether Switch (if equipped)

If your snowmobile has a tether switch, remove the tether from the switch to make sure the engine stops immediately.

n Lighting

Check the headlight (high and low beam), taillight, and brake light. Replace burned out lamps before operating.

n Mirrors (if equipped)

Adjust the mirrors so they can be used to their full advantage.

n Operating Area

Before driving away, check your surroundings. Be aware of obstacles and make sure bystanders are a safe distance from the snowmobile.

OPERATION

Starting the Engine

NOTICE: Engaging the starter when the engine is running WILL result in serious

1. Turn the key to the ON position.

2. Pull the engine stop switch up to the RUN position.

3. If equipped with electric start, turn the key to START to crank the

4. If not equipped with electric start, grasp the starter handle and pull

TIP: Don't pull the starter rope to the fully extended position and don't allow it to

5. If the engine does not start after several attempts, slightly depress

CAUTION! To avoid injury and/or engine damage, do not operate the electric starter or pull-rope starter while the engine is running.

NOTICE: Operating the vehicle immediately after cold starting could cause

Restarting an Engine

If the rider stops the engine by pushing the engine stop switch down, restart the engine using the normal starting procedure. If the engine fails to start using the normal procedure:

1. Push the engine stop switch down to the OFF position.

2. Turn the key to the OFF position.

3. With both switches OFF, squeeze and hold the throttle in the wide

4. Crank the engine several times to clear the engine.

5. Release the throttle.

6. Restart the engine using the normal starting procedure.

engine damage, especially if the transmission is in reverse. Never engage the starter when the engine is running.

engine. Release the key to the ON position when the engine starts.

slowly until the recoil engages; then pull abruptly to crank the engine.

snap back into the housing. Damage may result.

the throttle (no more than 1/4I open) while cranking the engine. When the engine starts, immediately release the throttle.

engine damage. Allow the engine to warm up for several minutes before operating the vehicle. If cold drive-away is attempted, the engine RPM may stumble slightly to protect the engine.

open position.

OPERATION

Engine Break-In

No single action on your part is as important to long, trouble-free snowmobile life as proper break-in of a new or rebuilt engine. Premix the first tank of fuel with one pint of Polaris injection oil for each five gallons of fuel. This, in addition to the lubrication supplied by the injection system, will assure proper engine break-in.

NOTICE: Excessive heat build-up during the first three hours of operation will

damage close-fitted engine parts. Do not operate at full throttle or high speeds for extended periods during the first three hours of use. Vary the throttle openings and vehicle speeds to reduce friction on all close-fitting machined parts, allowing them to break in slowly without damage.

Use of any lubricants other than those recommended by Polaris may cause serious engine damage. We recommend the use of Polaris lubricants for your vehicle.

Drive with extra caution during the break-in period. Perform regular checks on fluid levels, lines, and all other important areas of the snowmobile.

OPERATION

Engine Break-In

Oil Injection System

Always check and fill the oil bottle when refueling. See page 65.

NOTICE: Serious engine damage can occur without the proper lubrication.

Oil Recommendations

This snowmobile is equipped with a variable exhaust system (VES). Engine lubrication comes from oil added to the fuel and oil injection systems.

Polaris recommends using Polaris Semi-Synthetic Oil for premixing the first tank of fuel at 40:1 (one pint of oil per 5 gallons of fuel) and for the first fill of the oil tank. After this initial treatment, Polaris recommends the use of VES Gold Plus Synthetic 2-cycle oil. See page 110 for the part numbers of Polaris products.

Never mix brands of oil. Serious chemical reactions can cause injection system blockage, resulting in serious engine damage. Oils may also be incompatible and the result could be sludge formation, filter blockage, and reduced cold weather flow rates. All Polaris oils are compatible with each other.

Check the oil bottle level often during the first tank of fuel. If the oil level doesn't go down, contact your dealer immediately.

OPERATION

Track Warm-Up

WARNING! A loose track or flying debris could cause serious injury or death.

Stand clear of the front of the snowmobile and the moving track. Never hold the snowmobile up or stand behind it while warming up the track. Do not use excessive throttle during warm-up or when the track is free-hanging. Use a stable rear support.

WARNING! Use of traction products such as studs, ice growsers, etc. will increase the possibility of track damage and/or failure. This could cause loss of control, resulting in serious injury or death. Always inspect for track damage before operating the snowmobile.

Follow these steps to ensure proper warm-up of the engine, drive train and track.

1. Use an appropriate stand to securely support the rear of the snow-

mobile at the rear bumper. The track should be about 4I (10 cm) off the ground.

2. Start the engine and allow it to warm up two to three minutes.

3. Depress the throttle abruptly and allow the track to rotate several

revolutions.

TIP: It will take longer to warm up the track sufficiently during colder outdoor

temperatures.

4. Release the throttle, apply the brakes, shut off the engine and lower

the snowmobile to the ground.

5. Grasp the skis by their front loops and move them from side to side

to loosen snow and ice.

Slide Rail and Track Cooling

NOTICE: Inadequate cooling and lubrication will lead to overheating of the slide

rail and track, resulting in premature wear and failure. Reduce speeds and frequently drive into fresh snow to allow adequate cooling and polishing of the slide rail and track surfaces. Avoid operating on ice, hard-packed surfaces or roads.

OPERATION

WARNING

Fuel

Gasoline is highly flammable and explosive under certain conditions.

• Always exercise extreme caution whenever handling gasoline.

• Always refuel outdoors or in a well-ventilated area.

• Always turn off the engine before refueling.

• Do not overfill the tank. Do not fill the tank neck.

• Do not smoke or allow open flames or sparks in or near the area where refu-

eling is performed or where gasoline is stored.

• If gasoline spills on your skin or clothing, immediately wash it off with soap

and water and change clothing.

• Never start the engine or let it run in an enclosed area. Engine exhaust fumes

are poisonous and can cause loss of consciousness or death in a short time.

The engine exhaust from this product contains chemicals known to cause cancer, birth defects or other reproductive harm. Operate this vehicle only outdoors or in well-ventilated areas.

Fuel Recommendation

For peak performance, Polaris recommends the use of 91 octane fuel or higher. Although 87 octane fuel is usable, some engine performance will be lost and fuel economy will decrease. Do not use lower than 87 octane fuel. Do not use fuel containing more than 10% ethanol. Never use E85 fuel in your snowmobile.

NOTICE: Operating with obstructed fuel systems will result in serious engine

damage. Perform maintenance as recommended. Prolonged exposure to petroleum based products may damage paint.

Always protect painted surfaces when handling fuel.

OPERATION

10% ETHANOL

24 OHM

NON-ETHANOL

160 OHM

Resistor

Fuel Resistor

This snowmobile is equipped with a feature that allows the engine controller to select the proper operating software based on the type of fuel being used. The proper fuel resistor must be installed to match the type of fuel you are using.

The snowmobile comes from the factory with the resistor installed that should be used when operating with fuel containing up to 10% ethanol. The resistor is labeled “10% ETHANOL 24 OHM” (see illustration).

The resistor is installed into the wiring harness on the left side of the snowmobile just above the top of the oil bottle (see photo).

If the snowmobile is operated with non-ethanol fuel be sure to install the resistor labeled “NON-ETHANOL 160 OHM”. This resistor is provided in the tool kit.

NOTICE: Engine damage may occur if ethanol fuel is used while the non-etha-

If you’re unsure of the type of fuel in the fuel tank, make sure the “10% ETHANOL 24 OHM” resistor is installed. This is the preferred default and will provide the most engine protection.

nol fuel resistor is installed. The check engine light may also display in this condition as this could cause detonation.

Fuel System Deicers

If you use non-ethanol fuel (sometimes labeled “non-oxygenated”), Polaris recommends the regular use of 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. See page 110 for the part numbers of Polaris products.

If you use fuel with up to 10% ethanol (sometimes labeled “oxygenated”) do not add deicers or additives that contain any form of alcohol.

OPERATION

“Add”

Mark

n Oil

Low Oil Level

Always maintain the oil level between the “add” mark and the bottle neck. Do not fill the bottle neck. See page 61 for oil recommendations.

1. Immediately stop the engine if the

low oil indicator light comes on.

2. Open the left side panel.

3. View the oil level in the oil bottle.

4. Add oil as needed before operating.

NOTICE: Operating the snowmobile without adequate engine lubrication can

The oil bottle cap is vented to allow proper oil flow. See your Polaris dealer for recommended replacement parts.

result in serious engine damage. Always check the oil level when refueling. Add oil as needed.

OPERATION

n Engine Stop Switch

Push down on the engine stop switch (+) to ground out the ignition and stop the engine quickly. Pull the switch up to the ON position to allow restarting.

n Throttle Safety Switch

The throttle safety switch is designed to stop the engine whenever all pressure is removed from the throttle lever and the throttle cable or valves do not return to the normal closed position.

WARNING! Operating the snowmobile with a faulty throttle safety switch can result in serious injury or death in the event of an accident. If the throttle safety switch does not shut off the engine during a carburetor/throttle system malfunction, immediately push down the engine stop switch. Do not start the engine again until the malfunction has been corrected by your dealer.

Test the throttle safety switch system daily before operation.

1. Sit on the seat.

2. Start the engine and allow it

to idle.

3. Hold the throttle lever pin

stationary by exerting pressure on the pivot pin in the direction shown in the illustration.

4. Apply a slight amount of throttle. A properly functioning switch

must shut down the engine.

OPERATION

Throttle Lever

WARNING! An improperly functioning throttle lever may cause erratic

snowmobile behavior and loss of control, which could result in serious injury or death. If the throttle lever does not work properly, DO NOT start the engine.

If the engine stops abruptly when the throttle lever is released:

1. Turn the ignition switch to OFF.

2. Visually inspect the throttle cable and carburetor/throttle body to

determine what caused the safety switch to activate.

3. Test the throttle lever by compressing and releasing it several times.

The lever and cable must return to the idle position quickly and completely.

4. If the throttle lever operates properly, turn the ignition switch on and

go through normal starting procedures.

5. If the engine doesn't start, take the snowmobile to an authorized

Polaris dealer for service.

Excessive freeplay in the throttle cable may cause the safety switch to activate, preventing the engine from starting. If this occurs, return the snowmobile to an authorized Polaris dealer for service.

If an emergency exists and it's necessary to start the engine, the throttle safety switch and engine stop switch may be disconnected from the wire harness. When these switches are disconnected, the ignition key switch must be used to shut off the engine. DO NOT continue to operate the snowmobile with the throttle safety switch disconnected. Return the snowmobile to an authorized Polaris dealer for service as soon as possible.

OPERATION

Emergency Stopping

The following chart lists methods for stopping the snowmobile in the event of an emergency. See page 66 for more information about the engine stop switch and throttle safety switch.

SYSTEM WHAT IT DOES

Ignition Switch Interrupts ignition circuit

Brake Slows jackshaft

Engine Stop Switch Interrupts ignition circuit

Throttle Safety Switch Interrupts ignition circuit

Tether Switch (Option) Interrupts ignition circuit

OPERATION

WARNING

Electronic Reverse (PERCt)

Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Damage will occur to the chaincase or transmission if shifting is attempted when the engine is operating above idle speed.

• Shift to or from reverse only when the snowmobile is stopped and when

engine speed is at idle.

• Look behind the vehicle before and while backing.

• Avoid sharp turns.

• Apply throttle slowly.

Electronic reverse will activate only if the engine RPM is below 4000.

NOTICE: Engaging the starter when the engine is running WILL result in serious

engine damage, especially if the transmission is in reverse. Never engage the starter when the engine is running.

OPERATION

Electronic Reverse (PERCt)

Engaging Reverse

1. Stop the snowmobile and leave the engine idling.

2. Make sure the area behind your vehicle is clear.

3. Push the yellow reverse button on the left-hand control for one sec-

ond, then release. The engine will automatically reduce RPM and start a reverse rotation. A flashing reverse light on the instrument panel will indicate that the transmission is in reverse.

4. Apply the throttle slowly to make sure the transmission is in

reverse.The maximum engine RPM will be 6000 when in reverse.

TIP: If the engine stops running, the snowmobile will be in forward gear when it's

restarted.

Disengaging Reverse

1. Stop the snowmobile and leave the engine idling.

NOTICE: Engaging the starter when the engine is running WILL result in serious

2. Push the yellow reverse button for one second and release. The

3. Apply the throttle slowly to make sure the transmission is in for-

engine damage, especially if the transmission is in reverse. Never engage the starter when the engine is running.

engine will slow and begin to rotate forward. The light on the instrument panel will shut off.

ward.

OPERATION

Daily Storage

At the end of each ride, park the snowmobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4I (10 cm) off the ground.

Remove the key and cover the snowmobile.

Towing

For your safety, do not attempt to use a tow hitch until you've read the following warnings and understand the proper hitch functions.

WARNING! Objects towed with a rope have no braking power and can easily collide with the rear of the snowmobile or other objects, resulting in serious injury or death. DO NOT tow toboggans, sleds, saucers, or any type of vehicle with a rope. Only a stiff metal pole connecting the towed object and the tow hitch on the snowmobile should be used. If passengers are to be towed on a toboggan or sled, make sure the pole is at least four feet (1.2 meters) long to prevent any possibility of contact between the snowmobile's track and a person riding in the towed object.

WARNING! Braking distances increase when towing loads. Slow down to maintain control of the snowmobile.

If the snowmobile becomes inoperable and must be towed, and if it isn't possible to use a rigid tow bar, attach the tow rope to the ski spindles (not to the ski loops) to prevent damage to the steering components. Remove the drive belt before towing, and have someone ride on the towed snowmobile to operate the brake and steering when necessary.

NOTICE: Towing a disabled snowmobile with the drive belt in place can result in

serious damage to the engine and drive system. Always remove the drive belt from a disabled snowmobile before towing.

MAINTENANCE

Emission Control Information

Any qualified repair shop or qualified person may maintain, replace, or repair the emission control devices or systems on your snowmobile.

Emission Control Label

Your snowmobile is equipped at the time of sale with an emission control information (ECI) label and a factory-installed emissions information hangtag. These items are required by U.S. Environmental Protection Agency regulations. The ECI label is permanently affixed to either the right side of the tunnel or the engine recoil cover. The ECI label should not be removed, even after you purchase the snowmobile. You may remove the factory-installed emissions information hangtag, which is intended solely for your use in making a purchasing decision.

Emission Control Maintenance Requirements

Your snowmobile is certified to operate on gasoline with a minimum octane level of 87 (R+M)/2. If your snowmobile is equipped with a check engine light and it comes on, you must take your snowmobile to a qualified dealer for diagnostic service. Specifications and adjustments for engine tune-ups are located in the Service Manual, which is available to your qualified service technician. Reverse (if equipped) must not be engaged during engine tune-ups.

Owner's Responsibilities

Please read the Snowmobile Engine Emissions Limited Warranty, and read the maintenance section of your owner's manual. You are responsible for ensuring that the specified maintenance is performed. Polaris recommends that you contact an authorized Polaris dealer to perform any service that may be necessary.

MAINTENANCE

Polaris Recommended Maintenance Program

To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as outlined in this manual. Record maintenance and service in the Maintenance Log beginning on page 125.

The recommended maintenance schedule on your snowmobile calls for service and maintenance inspections at 150 miles (240 km), 500 miles (800 km) and 1000 miles (1600 km). These inspections should be performed by a qualified service technician. For continued optimum performance and component life, continue maintenance checks at 1000 mile (1600 km) intervals.

All necessary replacement parts and labor incurred, with the exception of authorized warranty repairs, become the responsibility of the registered owner. If, during the course of the warranty period, part failures

occur as a result of owner neglect in performing recommended regular maintenance, the cost of repairs are the responsibility of the owner.

Personal safety is critical when attempting to service or make adjustments to your snowmobile. If you're not familiar with safe service or adjustment procedures and the use of tools, or if you don't feel comfortable performing these tasks yourself, contact an authorized Polaris dealer for service.

NOTICE: Hot components can cause damage to plastic. Always make sure the

exhaust system and engine have cooled before tipping the snowmobile on its side for service or inspection.

MAINTENANCE

Periodic Maintenance Interval Table

The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. When inspection reveals the need for replacement parts, always use genuine Polaris parts, available from your Polaris dealer.

Item See

Clutch Alignment Offset (without belt)

Drive Belt Condition 95 II II

Clutches 94 CCC

Belt Tension -- II II

Clutch Sheaves 94 II II

Engine Mounts -- II II

Recoil Rope -- II II

Cylinder Head Bolts -- II I

Cylinder Base Nuts -- III I

Ignition Timing BTDC -- II I

VES System -- CC C I

Coolant Level 85 IIRI

Coolant Hose -- II II

Coolant Circulation -- II I

Coolant Leaks -- II II

Spark Plugs 83 II IRI

Exhaust Pipe 88 II

Exhaust Retaining Springs

I - Inspect (clean, adjust, tighten, lubricate, replace if necessary) C - Clean R - Replace L - Lubricate

Page

150 mi.

(240 km)

94 II I

ENGINE/COOLING

88 II II

CLUTCH

500 mi.

(800 km)

Frequency

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

MAINTENANCE

Periodic Maintenance Interval Table

Item See

Hose Routing -- II II

Hose Condition -- II II

Fluid Leaks -- II II

Brake Pads 90 IIII

Brake Disc -- II II

Parking Brakes 56 II II

Brake System 55, 90 I

Brake Fluid 91 R

Idle RPM -- II I

Throttle Lever 67 II I I I

Oil Pump Lever (synchronize)

Throttle Cable 80 LL L

Throttle Position Sensor -- II I

Fuel Lines 81 II I I I

Fuel Filter (Replace) 81 Initial Every

Oil Filter 84 RR

Oil Lines 84 III

Air Box -- II I I I

Auxiliary Shut-Off Switch

Throttle Safety Switch 66 III I I

Ignition Switch -- II I I I

Taillight 58 III I I

Brakelight 58 II I I I

Headlight 58 II I I I

Page

150 mi.

(240 km)

FUEL MANAGEMENT

-- II I

ELECTRICAL

58 II I I I

BRAKES

500 mi.

(800 km)

Frequency

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

MAINTENANCE

Periodic Maintenance Interval Table

Item See

Ski Toe Alignment -- II I

Suspension Mounting Bolts

Steering Fasteners -- III IC

Rear Suspension Fasteners

Rear Suspension Bushings

Suspension Shock Oil -- R

Rear Shock Threads 80 L

Cooling Fins and Shroud

Drive Shaft Bearing 80 LLL I

Skags (Wear Bars) 105 II I I I

Ski Saddle/Spindle Bolts -- II I I I

Drive Chain Tension 89 II I I I

Hood and Side Panel Fasteners

Rear Wheel Idler Bolts 101 II I I I

Idler Bolt Jam Nut 101 II I I I

Camber Alignment -- II I

Handlebar Centering -- I

Tether Switch and Strap 58 II I I I

Track Alignment 102 II I I I

Track Tension 100 III I I

Front Limiter Strap -- II I I I

Rail Slide Condition 106 I

Chaincase Oil 78 IR I R I

Page

150 mi.

(240 km)

-- II I I I

106 III

-- II II

77 II I I I

(800 km)

CHASSIS

500 mi.

Frequency

1000 mi.

(1600 km)

2000 mi.

(3200 km)

Pre-

Season

I - Inspect (clean, adjust, tighten, lubricate, replace if necessary) C - Clean R - Replace L - Lubricate

MAINTENANCE

Strap

1/4-Turn Fasteners

Hood/Side Panel

To open a side panel, rotate the two 1/4-turn fasteners at the upper edges of the side panel. Release the side panel strap at the lower edge of the panel.

To remove an open side panel, pull the panel outward to release the tabs at the lower edge of the panel.

Removing the hood is not recommended. Any service requiring the removal of the hood should be performed by an authorized Polaris dealer.

MAINTENANCE

Fill Plug

Lubrication

n Chaincase Oil

Check and change the chaincase oil at the intervals outlined in the maintenance charts beginning on page 73. Maintain the oil level at the top of the fill plug hole. Polaris recommends the use of Polaris Synthetic Chaincase Lube. See page 110 for the part numbers of Polaris products.

Oil Level

1. Position the vehicle on a level

surface.

2. Remove the fill plug.

3. Using a funnel, slowly add the

recommended oil until the fluid begins to overflow.

4. Wipe the fill area with a clean

cloth.

5. Reinstall the fill plug. Torque to

6-10 ft. lbs. (8-13 Nm).

MAINTENANCE

Lubrication

n Chaincase Oil

Oil Change

1. Position the vehicle on a level surface.

2. Place a drain pan under the drain plug. Remove the drain plug.

Allow the oil to drain completely.

3. Clean off all metal shavings from the plug. Install a new sealing

washer on the drain plug.

TIP: The sealing surfaces on the drain plug and the oil tank should be clean and

free of burrs, nicks or scratches.

4. Reinstall the drain plug. Torque to 6-10 ft. lbs. (8-13 Nm).

5. Remove the fill plug. Clean off all metal shavings from the plug.

6. Using a funnel, slowly add the recommended oil until the fluid

begins to overflow. Fluid capacity is 9 oz. (266 ml).

7. Wipe the fill area with a clean cloth.

8. Reinstall the fill plug. Torque to 6-10 ft. lbs. (8-13 Nm).

MAINTENANCE

Lubrication

Rear Shock Body Threads

Lubricate rear shock body threads seasonally. We recommend the use of Polaris Shock Thread Lubricant, a silicone spray lubricant. This lubricant is specifically designed for cold temperatures and high loads. Other silicone lubricants will not perform as well. See page 110 for the part numbers of Polaris products.

Driveshaft Bearing

Inject grease into the fitting on the speedometer sensor housing until grease purges from the seal on the inside of the tunnel. This should take approximately two pumps. Do not use more than four pumps.

Throttle Cable

Lubricate the throttle cable lightly with grease or oil. With the engine off, turn the handlebars to the left and lubricate liberally as shown.

MAINTENANCE

Intake Filters

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

Fuel Pump

All fuel pump service must be performed by an authorized Polaris dealer. Do not attempt to service the fuel pump.

Fuel Filter/Fuel Lines

See your Polaris dealer for replacement of the fuel filter. Have the filter replaced initially at 1000 miles (1600 km), then every 2000 miles (3200 km) thereafter.

Inspect the fuel lines regularly for signs of deterioration or damage. Always check fuel line condition after periods of storage. Normal deterioration from weather and fuel compounds may occur. Replace worn or damaged fuel lines promptly.

NOTICE: Kinking the fuel lines or using a pliers or similar tools to remove fuel

lines may cause damage to the lines. If a fuel line has been damaged or kinked, replace it promptly.

MAINTENANCE

Spark Plugs

Spark Plug Recommendations

A new engine can cause temporary spark plug fouling due to the preservative added during the assembly process. Avoid prolonged idle speeds, which cause plug fouling and carbonization.

Refer to your Owner's Manual Supplement for the specific spark plug to be used in your snowmobile.

Change the spark plugs every 2000-2500 miles (3200-4000 km).

• Use recommended spark plugs with the proper gap.

• Use only resistor-type spark plugs.

• Torque spark plugs to 18-22 ft. lbs. (24-30 Nm).

• Always carry spare spark plugs.

NOTICE: Using non-recommended spark plugs can result in serious engine

damage. A spark plug with a heat range too high will always cause engine damage if the engine is operated in conditions more severe than intended for that plug. Always use the spark plugs recommended for your snowmobile. See your Owner’s Manual Supplement.

MAINTENANCE

Spark Plugs

Spark Plug Inspection

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

CAUTION! A hot exhaust system and engine can cause burns. Wear protective gloves when removing a spark plug for inspection.

1. Remove the left side panel.

2. Remove the spark plug cap.

3. Using the special wrench provided in the tool pouch, rotate the

spark plug counter-clockwise to remove.

4. Reverse the procedure for spark plug installation. Torque to specifi-

cation.

5. Reinstall the spark plug cap.

Spark Plug Condition

Normal Plug

The normal insulator tip is gray, tan or light brown. There will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service.

TIP: The tip should not be white. A white insulator tip indicates overheating,

caused by use of an improper spark plug or incorrect carburetor/throttle body adjustments.

Wet Fouled Plug

The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire nose. Generally, the electrodes are not worn. General causes of fouling are excessive oil or use of non-recommended injection oil.

MAINTENANCE

Oil Lines

Inspect oil line condition every 1000 miles (1600 km).

Oil Filter

The oil filter is located at the side of the oil tank. Have your dealer change the oil filter and bleed the system annually or every 1000 miles (1600 km).

TIP: The direction of the arrows indicates

the direction of flow through the filter.

MAINTENANCE

“Full Cold” Mark

Cooling System

Coolant

The coolant supplied in the system at the factory is a 50/50 mixture of ethylene-glycol and distilled water, which will provide adequate freeze protection under most conditions. If the vehicle will be stored or operated at extremely low temperatures, greater protection may be required. Please see your Polaris dealer.

When adding or changing coolant, Polaris recommends using Premium 60/40 anti-freeze coolant, which is already premixed and ready to use. Do not dilute with water. Never exceed a 60% antifreeze/40% water mixture. See page 110 for Polaris products.

Never add tap water to the cooling system. Minerals cause deposits and may react adversely with the metals in the engine and cooling system.

n Coolant Level

The engine coolant level is controlled by the recovery system. The recovery system components are:

• Coolant bottle/overflow tank

• Pressure cap

• Connecting hoses Always maintain the coolant level at or

slightly above the FULL COLD mark on the coolant bottle (when the engine is cold).

1. Stop the engine.

2. Open the right side panel.

3. View the coolant level in the coolant

bottle.

4. Add coolant as needed.

NOTICE: Operating the snowmobile with insufficient coolant will result in over-

heating and serious engine damage. Always maintain the coolant level as recommended.

MAINTENANCE

Cooling System

Engine Overheating

The over-temperature indicator on the instrument cluster will illuminate when the engine is overheating. The indicator will flash when engine temperature reaches critical levels.

Illuminated Indicator

Take action to cool the engine:

• Drive in loose snow.

• View the coolant level. Do not open the pressure cap while the engine is hot. Add coolant if the level is low.

• Stop the engine and allow it to cool down.

If you must continue to operate while the indicator light is illuminated, drive slowly and stop the engine frequently to allow it to cool down.

Flashing Indicator

If the indicator flashes, continued operation could result in serious engine damage. The system will automatically reduce engine power and create a misfire condition. Stop the engine immediately. Allow the engine to cool down.

If engine overheating seems to be caused by something other than poor cooling conditions, see your dealer for service.

Flushing the Cooling System

To ensure that the coolant maintains its ability to protect the engine, drain the system completely every two years and add a fresh mixture of antifreeze and distilled water. This service must be performed when the engine is cold. Ask your Polaris dealer to check the coolant when he performs the fall tune-up on your snowmobile.

MAINTENANCE

Cooling System

Bleeding the Cooling System

CAUTION! Steam and hot liquids will cause burns to your skin. Never bleed the

cooling system or remove the pressure cap when the engine is warm or hot.

Use of a non-standard pressure cap will not allow the recovery system to function properly. If the pressure cap needs replacement, contact your dealer for the correct part.

NOTICE: If coolant flow becomes restricted or plugged, coolant loss, air lock or

1. Position the vehicle so that the top of the tunnel is level. Elevate the

2. Make sure the engine is cold before continuing.

3. Remove the right side panel.

4. Fill the coolant bottle with properly mixed coolant to the maximum

5. Remove the bleed screw from the water outlet manifold and/or the

6. Add coolant to the coolant bottle to the maximum mark.

7. Reinstall the side panel. Always ensure that the hood and side pan-

8. Start the engine and run at a fast idle for two to three minutes.

TIP: Engine temperature should reach 130_ F (54_ C) before continuing.

9. Stop the engine and check the coolant bottle level. Add coolant as

10. Carefully and briefly touch the top of the tunnel cooler under the

11. Remove the side panel. Reinstall the pressure cap. Reinstall the side

12. Carefully lower the front end of the snowmobile.

engine damage may result.

front of the vehicle slightly if necessary.

mark. Do not install the pressure cap at this time.

thermostat housing. Allow the coolant to bleed through the system until it runs out the bleed holes. Reinstall the bleed screw into the manifold.

els are securely in place before starting the engine.

Loosen the bleed screw occasionally to purge any trapped air.

needed. Reinstall the side panel.

seat. If the system is bled properly, the cooler will be warm to the touch. If not, repeat step 8. Lift the front of the snowmobile slightly to assist in the bleeding.

panel.

MAINTENANCE

Exhaust System

Check the exhaust system for wear or damage at approximately 2000 miles (3200 km). Always allow the engine and exhaust system to cool completely before inspecting.

CAUTION! Hot exhaust system parts can cause burns. Allow adequate time for the exhaust system to cool. Never perform this procedure with the engine running.

1. Open the side panels and remove the hood. See page 77.

2. Inspect the muffler and pipes for cracks or damage.

3. Check for weak or missing retaining springs or damper/support

grommets.

4. Check for loose clamps on the pipe covers.

MAINTENANCE

Jam

Nut

Adjuster

Bolt

Drive Chain Tension

Check drive chain tension weekly and before each long trip.

1. Remove the side panels.

2. Rotate the driven clutch

counter-clockwise to move all chain slack to the tensioner side. Lock the brake lever lock, or have an assistant hold the brake lever firmly.

3. Loosen the adjuster bolt jam

nut.

4. Finger tighten the adjuster bolt

until it can no longer be adjusted by hand, then back off 1/4 turn.

5. Tighten the jam nut while

holding the adjuster bolt. Torque to 21 ft. lbs. (28 Nm).

6. Reinstall the side panels.

7. Release the brake lever lock.

MAINTENANCE

Brakes

Hydraulic Brake Inspection

Inspect the brake lever reserve before each use of the snowmobile. See page 55.

Brake pads must be replaced when the brake pad material becomes thinner than the backing plate (approximately 1/16I). A kit is available for replacing brake pads. See your dealer.

WARNING! Brake failure during operation can result in serious injury or death. Properly functioning brakes are vital to your safety. Be sure the brake pads do not drag on the disc and that brake lever travel is not excessive. Always replace brake pads when the brake pad material becomes thinner than the backing plate

(approximately 1/16

Brake Components

1. Brake Caliper

2. Brake Disc

3. Brake Pad Material (Replace

when thickness is less than 1/ 16I/1.5 mm).

Excessive Lever Travel

Hydraulic brakes are self-adjusting, but if excessive brake pad clearance develops, bring the snowmobile to an authorized Polaris dealer for inspection and adjustment.

I).

MAINTENANCE

Brakes

Brake Fluid

The brake fluid level can be seen through a plastic sight glass in the brake reservoir. If the fluid is sufficient, the sight glass will be black. If the sight glass is any color other than black, add brake fluid.

Replace brake fluid at least every two years with Polaris DOT 4 high temperature brake fluid. See page 110 for the part numbers of Polaris products.

WARNING! After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle. Brake fluid is hygroscopic, meaning it rapidly absorbs moisture from the air. The moisture causes the boiling temperature of the brake fluid to drop, which can lead to early brake fade and the possibility of accident or serious injury.

WARNING! Keep the master cylinder cover free of dirt and debris. The vent slits allow for diaphragm movement, and if they become plugged, movement of brake fluid below the diaphragm may be restricted, altering brake function.

NOTICE: Brake fluid will damage labels, paint and some plastics. Always wipe

up spills immediately.

MAINTENANCE

Brakes

Bleeding the Hydraulic Brake System

Air in the hydraulic brake system will cause spongy brake lever action. Bleed the system before operating the snowmobile.

WARNING! Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an accident and lead to serious injury or death. Never operate the vehicle with a spongy-feeling brake lever.

During the bleeding procedure, keep the brake handle as level as possible. The reservoir must be in this position to minimize the possibility of air entering the system through the reservoir vent.

1. Remove the brake master cylinder reservoir cover and gasket.

2. Fill the master cylinder reservoir to between the MIN and MAX

marks or 1/4-5/16I (.6-.8 cm) below the lip of the reservoir opening. Reinstall the gasket and cover.

3. Slip a rubber tube over the ball of the bleeder valve and direct the

flow of fluid into an approved container.

4. Squeeze the brake lever a full stroke. Then unscrew the bleeder

valve 3/4 of a turn to release air.

5. Close the bleeder valve and release the brake lever.

6. Repeat steps 4 and 5 until fluid flows from the bleeder valve in a

solid stream free of air bubbles.

WARNING! Overfilling the master cylinder leaves no room for fluid expansion and may cause the brakes to lock, resulting in serious injury or death. Always add brake fluid to the fill line as recommended.

7. After bleeding is complete, refill the reservoir to the proper level.

See page 91.

8. Reinstall the gasket and cover.

MAINTENANCE

Lights

When servicing a halogen lamp, avoid touching the lamp with bare fingers. Oil from your skin leaves a residue, causing a hot spot that will shorten the life of the lamp. If fingers do touch a lamp, clean it with denatured alcohol.

Headlight Lamp Replacement

1. Peel back the foam shield covering the headlight assembly.

2. Remove the wire harness connector from the back of the headlight.

3. Grasp the bulb housing and turn it counter-clockwise to remove the

bulb.

4. Apply dielectric grease to the socket and install the new bulb.

Rotate the bulb 1/4 turn clockwise to secure it.

5. Reinstall the connector to the back of the headlight.

6. Secure the foam shield.

Taillight/Brake Light Replacement

The taillight assembly is not serviceable. If the light fails to operate properly, replace the entire taillight assembly.

MAINTENANCE

Clutch System

Periodically inspect clutch sheaves for damage, wear or belt residue. To maintain optimum performance, clean with non-oil based cleaners such as isopropyl alcohol.

WARNING! If you become aware of higher than normal clutch engagement or an unusual vibration or shift pattern, see your dealer immediately. Do not operate the snowmobile until repairs have been made.

All clutch maintenance and repairs must be performed by an authorized Polaris dealer. Any unauthorized modifications to clutches, such as adding or removing weights, will void the warranty.

NOTICE: The bushings in the weights and rollers of Polaris clutches are made

Clutch Alignment Offset

Clutch alignment offset is important for maintaining optimum performance. See your dealer for service and adjustments. A special tool is required to check for proper alignment.

Clutch Center Distance

See your Owner's Manual Supplement for recommended center distance for your snowmobile. If adjustment is necessary, see your dealer.

of a material that may be damaged if lubricated. Do not lubricate clutch bushings.

MAINTENANCE

Clutch System

n Drive Belt Condition

Periodically check the condition and tension of the drive belt. Inspect the belt for signs of excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions exist. See Drive Belt Troubleshooting on page 115.

Always carry a spare drive belt. Store the spare belt in the belt clip located under the left side of the hood.

For improved drive-away during extremely cold temperatures, remove the belt and warm it to room temperature. Reinstall it before starting the snowmobile.

MAINTENANCE

Clutch System

n Drive Belt Deflection

Measure belt deflection with both clutches at rest and in their full neutral position.

Place a straight edge (1) on the belt and apply downward pressure while measuring at point 2. This measurement should be 1 1/4 inches (3.2 cm).

Drive Belt Adjustment

1. Loosen the 7/16-inch jam nut on the belt width adjuster.

2. Using a 1/8-inch Allen wrench, turn the set screw inward (clock-

wise) to increase the distance between the sheaves or outward (counter-clockwise) to decrease the distance.

3. Tighten the jam nut.

Polaris 2010 Rush User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual