Snowmobile Polaris 600 RUSH, 600 RUSH PRO-R, 800 RUSH, 800 RUSH PRO-R (2013 year). Manual - part 23

94

MAINTENANCE

Exhaust System

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

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

1. Open the side panels and remove the hood. See page 85.

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.

5. Reinstall the hood and side panels.

95

MAINTENANCE

Drive Chain Tension

Check drive chain tension at the intervals outlined in the maintenance 
charts beginning on page 81 and before each long trip. 

1. Remove the side panels.

2. Rotate the driven clutch coun-

ter-clockwise to move all 
chain slack to the tensioner 
side. Lock the brake 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.

Jam 

Nut

Adjuster 

Bolt

96

MAINTENANCE

Brakes

Hydraulic Brake Inspection

Inspect the brake lever reserve before each use of the snowmobile. See 
page 63.

Brake pads must be replaced when the brake pad material becomes thin-
ner than the backing plate (approximately 1/16 inch or 1.5 mm). A kit is 
available for replacing brake 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 inch or 1.5 mm).

Brake Components

1. Brake Caliper

2. Brake Disc

3. Brake Pad Material (Replace when 

thickness is less than 1/16 inch/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.

2

1

3

97

MAINTENANCE

Brakes

Brake Fluid

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

Replace brake fluid at least every two years with POLARIS DOT 4 high 
temperature brake fluid. See page 115 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.