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Snowmobile Polaris 600 RUSH (2010 year). Manual - part 10

1.38

General Information

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

2012 800 PRO RMK 155/163

Model Numbers:



800 PRO RMK 155



S12CG8GSA / S12CG8GEA / S12CG8GSB



S12CG8GSC / S12CG8GSL / S12CG8GSM



S12CG8GSP




800 PRO RMK 163



S12CH8GSA / S12CH8GEA / S12CH8GSB



S12CH8GSC / S12CH8GSL / S12CH8GSM



S12CH8GSP

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

S4359-8044-OL8G

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)

87/89/91+

(Up to10% Oxygenated)

91+

(Non-Oxygenated)

Clutch Settings

ALTITUDE

meters

(feet)

DRIVE CLUTCH

DRIVEN CLUTCH

Shift

Weight

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

1.39

General Information

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

NOTE: * = Rider weight with gear.

Track

Width - Inches (cm)

15 (38)

Length - Inches (cm)

155 (393.7)

163 (414)

Pitch



Plies

2.86

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 GR9A-EG

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

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)

16 (40.6)

1.40

General Information

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

SNOWMOBILE NUMBER
DESIGNATIONS

Model Number Designation

Example: S10BF6KSA

VEHICLE IDENTIFICATION NUMBER

VIN Number Designation

GROUP

MODEL

YEAR

MODEL

LINE

MODEL

TYPE

ENGINE

MODIFIER

VIN

IDENTIFIER

OPTION

IDENTIFIER

1st digit

2/3rd digit

4th digit*

5th digit*

6th/7th digits*

8th digit

9th digit**

B = Pro-Ride

C = Hybrid

A = Base Adventure

C = PRO-R Adv.

F = 120/121

D= LX

E= PRO-R LX

F = Rush Base

G = 155 Premium
H = 163 Premium

K = 144 Base

L = SB Assault 2”

M = 155 Base

N = 155 Assault RMK

P = Rush PRO-R

R = Switchback Base

S = Switchback

Premium

V = Limited Edition

W = SB Assault 1.35”

Y = Assault 155 2.4”

6G = 600 DC-CFI-2

6K = 600 DC-CFI-2+2

6N = 600 DC-CFI-4

8G = 794 DC-CFI-2

S = Standard

E = Europe

A = Base

B = 1st Opt.

C = 2nd Opt.

L = Electric Start

M = Electric

Start

P = Electric

Start

T = Track Opt.

*=digits that would transfer to 17 digit VIN and are used in digits 4-8 respectively



**=9th digit will be used on color/featured versions of models (not including the base)



First 3 digits and 9th digit are used in model number only. They are not used with the 17 digit VIN.

World Mfg. ID

Vehicle Descriptors

Vehicle Identifiers

Body S

Engine Size

Series

Check Digit

Mod

l Y

ear

Mfg. Lo

cation

Individual Serial No.

1.41

General Information

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

Tunnel Decal

The Tunnel Decal has the Model Number (1), V.I.N.
Number (2), and the Manufactured Date (3). These
numbers should be referred to in any correspondence
regarding warranty, service or replacement parts. The

machine model and V.I.N. number identification decal is
located on the right front side of the tunnel. The V.I.N. (2)
number is permanently stamped into the tunnel. The
model number is embossed on the decal.

PUBLICATION PART NUMBERS

2010 Publications

NOTE: Owner’s Manuals and electronic parts catalogs available at:



http://www.polarisindustries.com/en-us/RidersPortal.

2011 Publications

NOTE: Owner’s Manuals and electronic parts catalogs available at:



http://www.polarisindustries.com/en-us/RidersPortal.

MODEL

OWNER'S MANUAL

SUPPLEMENT

PARTS BOOK

600 RUSH

9922276

9922279

9922648 (S10BF6KSL)

9922280

MODEL

OWNER'S MANUAL

SUPPLEMENT

PARTS BOOK

600 RUSH

9922829

9922839 (RUSH)

9922830 (RUSH LX)

9922835 (PRO-R Retro LX)

9922841 (PRO-R)

9922831 (RUSH/LX)

9922836 (PRO-R)

800 RUSH

9922840 (RUSH)

9922833 (Retro LX)

9922837 (PRO-R Retro LX)

9922842 (PRO-R)

9922834 (RUSH/LX)

9922838 (PRO-R)

800 Switchback Assault

9922844

9922852

9922853

800 RMK 155

9922848

9922849

800 RMK Assault

9922850

9922851

800 PRO RMK 155/163

9922845 (155)
9922847 (163)

9922846

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