Snowmobile Polaris 600 RUSH (2010 year). Manual - part 4

 

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Snowmobile Polaris 600 RUSH (2010 year). Manual - part 4

 

 

1.14

General Information

9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

© 2011 Polaris Sales Inc.

2011 800 PRO RMK 155/163

Model Numbers:

800 PRO RMK 155

S11CG8GSA / S11CG8GSL / S11CG8GSB

S11CG8GSM / S11CG8GEA


800 PRO RMK 163

S11CH8GSA / S11CH8GSB / S11CH8GEA

NOTE:   OPTIONAL - USE 2 GRAM LIGHTER CLUTCH 
WEIGHTS WHEN OPERATING IN PROLONGED 
WARM TEMPERATURES (LATE FALL/SPRING 
SEASON) TO MAINTAIN PEAK OPERATING RPM.

Engine

Engine Type

Liberty Liquid-Cooled / 

Case Reed Induction

Model Number

S4092-8044-OO8G

Displacement / # Cylinders

794cc / 2

Bore (inches/mm)

3.34 / 85

Stroke (inches/mm)

2.75 / 70

Piston to Cylinder 
Clearance (inches/mm)

.004-.0055 / 0.103-0.141

Installed Ring Gap

(inches / mm)

.017-.025 / 0.450-0.650

Operating RPM +0-300

8250

Idle RPM ±200

1700

Engagement RPM ±200

3800

Exhaust Valve Spring

Orange

Thermostat Opening 
Temperature (° F/ ° C)

120 / 49

Fuel Delivery

Type - Number of Fuel 
Injectors

DC-CFI - 2

Throttle Body Marking

1204094

Throttle Body Bore

48mm

TPS Voltage @ Idle

(5 VDC +/- .01 Input)

0.94 +/- 0.01 VDC

Fuel Pressure - PSI (bar)

58-60 (4.0-4.1)

Fuel Octane (R+M/2)

10% Ethanol 24

 Resistor


Premium/Non-Ethanol 
160

 Resistor

<91 Octane

(Non-Oxygenated)

OR

87/89/91+

(Up to10% Oxygenated)

91+

(Non-Oxygenated)

Clutch Settings

ALTITUDE

meters

(feet)

DRIVE CLUTCH

DRIVEN CLUTCH

Shift 

Weight

Clutch 
Spring

Clutch 
Spring

Driven 

Helix

Gearing

0-600

(0-2000)

10-68

BLACK

140 - 330

7043342

BLACK

155-222

7043063

56/42 - .36

5135403

20:42 - 72

600-1200

(2000-4000)

10-66

1200-1800

(4000-6000)

10-64

1800-2400

(6000-8000)

10-62

2400-3000

(8000-10,000)

10-60

BLK/PUR

160-240

7043363

3000-3600

(10,000-12,000)

10-58

Drive Clutch Bolt Torque: 80 lb.ft. (108Nm)

Re-torque after running engine.

General

Width (in/cm)

46.5 / 118.1

Length (in/cm)

155 = 129/327.7
163 = 134/340.4

Height (in/cm)

51 / 129.5

Estimated Dry Weight (lb/kg)

155 = 431/195.5
163 = 437/198.7

Fuel (Gallons / Liters)

11.5 / 43.5

Oil (Quarts / Liters)

3.4 / 3.3

Cooling System 
Capacity(Qts/ L)

155=5.3/5.0
163=5.5/5.2

Brake Fluid

DOT 4

Drive Belt

Part Number

Width (inches / cm)

Side Angle

Circumference (inches / cm)

Center Distance (inches / cm)

3211115

1.460 / 3.7

26_

46.77 / 118.8

11.5 / 29.2

Chaincase

Center Distance (inches)

Top Gear (Stock)

Bottom Gear (Stock)

Chain (Stock)

Gear Lube

Capacity (oz / ml)

Reverse System

7.53

20
42
72

Polaris Synthetic (80W)

9 / 266

PERC

1.15

General Information

1

9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

© 2011 Polaris Sales Inc.

NOTE:  * = Rider weight with gear.

Track

Width - Inches (cm)

15 (38)

Length - Inches (cm)

155 (393.7)

163 (414)

Pitch

Plies

2.86

1

Lug Height - Inches (cm) 

2.4 (6.1) Series 5.1

Track tension sag in/cm 
with 10 lbs/4.54kg placed 
16 in/40cm ahead of rear 
idler shaft

3/8

- 1/2(1.0 - 1.3cm)

Electrical

Alternator Output

Operating Voltage

Watts @ 13.5 VDC 
(Total)

13.5 - 14.5 VDC

400

Ignition Timing 

18_ @1700 RPM

Coolant Temp = 120_F 

(49_C)

Spark Plug Gap 
in.(mm)

.027 (.70)

Spark Plug

NGK BPR9ES

Front Suspension

Suspension Type

PRO-RIDE RMK Adjustable

Shocks

Walker Evans HPG w/IFP

IFS Spring Rate

lbs/in (N/mm)

100 (17.4)

IFS Spring Installed 
Length - Inches (cm)

10.25 (26)

Front Vertical Travel

Inches (cm)

9 (22.9)

Ski Center Distance

Inches (cm)

Setup Width

39-40-41 (99.1-101.6-104.1)

36.26 (92)

Measured inside of spindles.

Camber Inches (cm)

1.95 

 0.31 (4.3  .8)

Toe Out Inches (mm)

0 -1/8

 (0 - 3)

Rear Suspension

Suspension Type

RMK Coil-Over 155/163

163= Tipped Rail

Front Track Shock

(FTS)

Walker Evans HPG w/IFP

FTS Spring Rate

lbs/in (N/mm)

150 (26.25)

FTS Spring Installed 
Length

Inches (cm)

8.50 (21.6)

Rear Track Shock

(RTS)

Walker Evans HPG w/IFP

Standard RTS Spring

Rate lbs/in (N/mm)

Installed Length In. (cm)

(Track off ground)

Rider Weight*

<160lbs./72kg

160-220lbs./72-99kg

220-280lbs./99-127kg

280-340lbs./127-154kg

PN: 7043714-133

210 (36.75)

10-3/4" (27.3)
10-3/8" (26.3)
10-1/8" (25.7)

9-3/4" (24.8)

CAUTION: Do not adjust STD 

spring length greater than 

11.0

"

 or less than 9-3/4

"

.

HD RTS Spring

Rate lbs/in. (N/mm)

Installed Length In. (cm)

(Track off ground)

Rider Weight*

250-300lbs./113-136kg

300-350lbs./136-159kg

PN: 7043740-067

250 (43.75)

10-1/8" (25.7)

10" (25.4)

CAUTION: Do not adjust HD 

spring length greater than
10-7/8

"

 or less than 9-7/8

"

.

Rear Travel

Inches (cm)

155/163 = 16 (40.6)

1.16

General Information

9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

© 2011 Polaris Sales Inc.

2012 600 RUSH

Model Numbers:

600 RUSH

S12BF6NSA / S12BF6NSL


600 RUSH PRO-R

S12BP6NSA / S12BP6NSB / S12BP6NSC / S12BP6NSL

S12BP6NEL / S12BP6NSM / S12BP6NSP

NOTE:   OPTIONAL - USE 2 GRAM LIGHTER CLUTCH 
WEIGHTS WHEN OPERATING IN PROLONGED 
WARM TEMPERATURES (LATE FALL/SPRING 
SEASON) TO MAINTAIN PEAK OPERATING RPM.

Engine

Engine Type

Liberty Liquid-Cooled / 

Case Reed Induction

Model Number

S4357-6044-OL6N

Displacement / # Cylinders

599cc / 2

Bore (inches/mm)

3.04 / 77.25

Stroke (inches/mm)

2.52 / 64

Piston to Cylinder 
Clearance (inches/mm)

.0033-.0054 / 0.085-0.137

Installed Ring Gap

(inches / mm)

.017-.025 / 0.450-0.650

Operating RPM ±200

8250

Idle RPM ±200

1700

Engagement RPM ±200

3800

Exhaust Valve Spring

Purple

Thermostat Opening 
Temperature (° F/ ° C)

120 / 49

Fuel Delivery

Type - Number of Fuel 
Injectors

DC-CFI - 4

Throttle Body Marking

1203978

Throttle Body Bore

46mm

TPS Voltage @ Idle

(5 VDC +/- .01 Input)

0.95 +/- 0.01 VDC

Fuel Pressure - PSI (bar)

58-60 (4.0-4.1)

Fuel Octane (R+M/2)

10% Ethanol 24

 Resistor


Premium/Non-Ethanol 
160

 Resistor

<91 Octane

(Non-Oxygenated)

OR

87/89/91+

(Up to10% Oxygenated)

91+

(Non-Oxygenated)

Clutch Settings

ALTITUDE

meters

(feet)

DRIVE CLUTCH

P2 DRIVEN CLUTCH

Shift 

Weight

Clutch 
Spring

Clutch 
Spring

Driven 

Helix

Gearing

0-600

(0-2000)

10-64

BLACK

120 - 310

7043681

130 - 180

Tabbed

7043515

58/42 - .45

5137176

23:39 - 72

600-1200

(2000-4000)

10-62

22:39 - 72

1200-1800

(4000-6000)

10-60

22:40 - 72

1800-2400

(6000-8000)

10-58

2400-3000

(8000-10,000)

10-56

20:41 - 72

3000-3600

(10,000-12,000)

10A-L

Drive Clutch Bolt Torque: 80 lb.ft. (108Nm)

Re-torque after running engine.

Clutch Settings (Electric Start Models)

ALTITUDE

meters

(feet)

DRIVE CLUTCH

P2 DRIVEN CLUTCH

Shift 

Weight

Clutch 
Spring

Clutch 
Spring

Driven 

Helix

Gearing

0-600

(0-2000)

10-64

BLK/GRN

120 - 340

7042083

130 - 180

Tabbed

7043515

58/42 - .45

5137176

23:39 - 72

600-1200

(2000-4000)

10-62

22:39 - 72

1200-1800

(4000-6000)

10-60

22:40 - 72

1800-2400

(6000-8000)

10-58

2400-3000

(8000-10,000)

10-56

20:41 - 72

3000-3600

(10,000-12,000)

10A-L

Drive Clutch Bolt Torque: 80 lb.ft. (108Nm)

Re-torque after running engine.

Track

Width - Inches (cm)

15 (38)

Length - Inches (cm)

121 (307)

Pitch

Plies

2.52

2

Lug Height - Inches (cm) 

Base

PRO-R

1.0 (2.54) (Hacksaw)

1.25 (3.175) (Ripsaw)

Track tension sag in/mm 
with 10 lbs/4.54kg placed 
16 in/40cm ahead of rear 
idler shaft

1/4



- 3/8

(6.3 - 9.6mm)

1.17

General Information

1

9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

© 2011 Polaris Sales Inc.

NOTE:  * = Rider weight in everyday clothing.

** = From full soft (CCW) position.

General

Width (in/cm)

48 / 121.9

Length (in/cm)

108 / 274

Height (in/cm)

48 / 121.9

Estimated Dry Weight (lb/kg)

469 / 212

Fuel (Gallons / Liters)

11 / 41.6

Oil (Quarts / Liters)

3.4 / 3.3

Cooling System Capacity(Qts/ L)

6 / 5.7

Brake Fluid

DOT 4

Drive Belt

Part Number

Width (inches / cm)

Side Angle

Circumference (inches / cm)

Center Distance (inches / cm)

3211122

1.460 / 3.7

26_

46.77 / 118.8

11.5 / 29.2

Chaincase

Center Distance (inches)

Top Gear (Stock)

Bottom Gear (Stock)

Chain (Stock)

Gear Lube

Capacity (oz / ml)

Reverse System

7.53

23
39
72

Polaris Synthetic (80W)

9 / 266

PERC

Electrical

Alternator Output

Operating Voltage

Watts @ 13.5 VDC (Total)

13.5 - 14.5 VDC

400

Ignition Timing 

18_ @1700 RPM

Coolant Temp = 120_F (49_C)

Spark Plug Gap in.(mm)

.027 (.70)

Spark Plug

NGK BPR9ES

Front Suspension

Suspension Type

PRO-RIDE (Fixed Camber)

Shocks

Base

PRO-R

Fox HPG w/IFP

Walker Evans Needle Piggyback

16 Click Compression Adjustable

Factory Setting** = 6

IFS Spring Rate

lbs/in (N/mm)

100 (17.5)

Preload - Inches (cm)

Base

PRO-R

3.25 (8.25)
2.875 (7.3)

Travel-Inches (cm)

9 (22.9)

Ski Center Distance

Inches (cm)

Setup Width

42.5 (108)

41.52 (105)

Camber Inches (cm)

NOT ADJUSTABLE

Toe Out Inches (mm)

0 -1/8

 (0 - 3)

Rear Suspension

Suspension Type

PRO-RIDE Progressive

Front Track Shock

(FTS)

Base

PRO-R

Fox HPG w/IFP

Walker Evans w/Remote Reservoir

16 Click Compression Adjustable

Factory Setting** = 2

FTS Spring Rate

lbs/in (N/mm)

120 - 310 (21 - 54.25)

FTS Spring Installed 
Length-Inches (cm)

Base Preload

PRO-R Preload

7.5 (19.05)

1.0 (2.54)
1.0 (2.54)

Rear Track Shock

(RTS)

Base

PRO-R

Fox HPG w/IFP

Walker Evans Needle

w/Remote Reservoir

16 Click Compression Adjustable

Factory Setting** = 4

Standard RTS Spring

Rider Weight*

120 - 260lbs.

Rate lbs/in (N/mm)

PN: 7043195-133

170 (29.75)

LW RTS Spring

Rider Weight*

90 - 150lbs.

Rate lbs/in (N/mm)

PN: 7041575-385

120 (21)

HD RTS Spring

Rider Weight*

240 - 335+lbs.

Rate lbs/in. (N/mm)

PN: 7043585-385

260 (45.5)

RTS Spring

Rider / Weight Setting

Spring length set to rider weight 

using adjustment gauge.

STD Gauge PN: 9923267

STD gauge supplied with vehicle. LW 
and HD springs - Use tape measure 
and RTS Spring Guide Table located 
in the Steering/Suspension Chapter.

Rear Travel

Inches (cm)

14 (35.6)

 

 

 

 

 

 

 

 

 

 

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