Content .. 9 10 11 12 ..

Snowmobile Polaris 600 RUSH (2010 year). Manual - part 11

1.42

General Information

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

2012 Publications

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



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

Service/Safety Bulletins

MODEL

OWNER'S

MANUAL

SUPPLEMENT

PARTS BOOK

600/800 RUSH
Models

9923316

600 RUSH - 9923330

600 RUSH Electric Start - 9923326
800 RUSH Electric Start - 9923328

800 RUSH - 9923332

600 RUSH PRO-R - 9923327
800 RUSH PRO-R - 9923329

600 RUSH - 9923331
800 RUSH - 9923333

600/800
Switchback Models

9923308

600 Switchback Electric Start - 9923309

800 Switchback - 9923336
600 Switchback - 9923338

800 Switchback Electric Start - 9923340

600 Switchback - 9923335

600 Adventure - 9923310

800 Switchback - 9923337

600 Switchback PRO-R - 9923339
800 Switchback PRO-R - 9923341

800 Adventure INTL. - 9923483

800 Switchback
Assault 1.3/2.0

9923351

1.3 - 9923359
2.0 - 9923352

1.3 - 9923360
2.0 - 9923353

600/800 RMK
Models

9923345

600 PRO RMK - 9923343

800 PRO RMK 155 - 9923346
800 PRO RMK 163 - 9923348

600 RMK 144 - 9923349
600 RMK 155 - 9923354
800 RMK 155 - 9923355

RMK Assault - 9923357

600 RMK 144/155 - 9923350

600 PRO RMK - 9923484

800 PRO RMK 155/163 - 9923347

800 RMK 155 - 9923356

RMK Assault - 9923358

BULLETIN

MODEL/YEAR

DESCRIPTION

S-09-10

600 RUSH/2010

August Build 2010 600 RUSH PRO-RIDE Inspections/Updates

(Select Models)

S-10-01

600 RUSH/2010

2010 600 RUSH PRO-RIDE ECU Reflash (All Models)

S-11-02

800 PRO RMK 155/163

800 RMK Assault

2011

2011 800 PRO RMK/RMK Assault Oil Hose Routing (All Models)

1.43

General Information

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

GENERAL REFERENCE

Standard Bolt Torque Specification

Metric Bolt Torque Specification

Grade 2

Grade 5

Grade 8

Bolt Size

Grade 2

ft-lb (Nm)

Grade 5

ft-lb (Nm)

Grade 8

ft-lb (Nm)

1/4-20

5 (7)

8 (11)

12 (16)

1/4-28

6 (8)

10 (14)

14 (19)

5/16-18

11 (15)

17 (23)

25 (35)

5/16-24

12 (16)

19 (26)

29 (40)

3/8-16

20 (27)

30 (40)

45 (62)

3/8-24

23 (32)

35 (48)

50 (69)

7/16-14

30 (40)

50 (69)

70 (97)

7/16-20

35 (48)

55 (76)

80 (110)

1/2-13

50 (69)

75 (104)

110 (152)

1/2-20

55 (76)

90 (124)

120 (166)

Bolt Size

GRADE

4.6

4.8

8.8/8.9

10.9

12.9

(

DRY

THREADS

)

.3/.5

.5/.7

1/1.3

1.5/2

.8/1.1

1/1.5

2/3

3/4.5

4/5

1.5/2.5

2/3

4.5/6

6.5/9

7.5/10

3/4

4/5.5

7.5/10

11/15

13/18

7/9.5

10/13

18/25

26/35

33/45

M10

14/19

18/25

37/50

55/75

63/85

M12

26/35

33/45

63/85

97/130

110/150

M14

37/50

55/75

103/140

151/205

177/240

M16

59/80

85/115

159/215

232/315

273/370

M18

81/110

118/160

225/305

321/435

376/510

1.44

General Information

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

Gasoline Volatility

Gasoline is given a Reid Vapor Pressure (RVP) number
which reflects its ability to vaporize or mix with air at a
given temperature range. Gasoline vapor pressure is
measured by putting a sample of fuel inside a closed
container and applying a specified amount of heat to the
container for a certain amount of time. RVP will vary from
about 7.0 PSI during the summer to approximately 13.5
PSI during the colder months. Service stations selling a
large volume of fuel will normally have the correct blend to
work well at all times throughout the year in their local
area.

When the weather is very cold, gasoline must be able to
vaporize very quickly in order for an engine to start and
warm up properly. If summer blend fuel is being used in the
winter, little or no vaporization will occur. Droplets will form
causing flooding and very hard starting.

If winter blend fuel is being used during the summer
months, it may cause vapor lock (boiling fuel) inside the
fuel lines, fuel pump, or carburetor. This will cause warm
engine driveability problems and hard starting when
warm.

Fuel / Oil Premix Ratios

Formula:

• 1 Gallon = 128 Ounces

• 128 / (Desired Ratio) = Ounces of oil for every 1

gallon of fuel.

• 128 / 40 (40:1 Ratio) = 3.2 ounces of oil for every 1

gallon of fuel.

Always mix ratio in 5 gallon increments.

NOTE: A 40:1 premix should always be used during
engine break-in or after rebuilding the engine.

Fuel Recommendations

For maximum performance, Polaris recommends the use
of 91 octane or higher non-oxygenated fuel. Although
lower octane and/or oxygenated 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
oxygenated fuel containing more than 10% ethanol. Never
use E85 fuel in your snowmobile.

NOTE: Operating with an obstructed fuel system 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.

Fuel System Deicers

If you use non-ethanol fuel (sometimes labeled “non-
oxygenated”), Polaris recommends the regular use of a
isopropyl-based fuel system deicer. Add one to two
ounces per gallon (8-16 ml per liter) of gasoline to prevent
damage resulting from fuel system icing. Never use
deicers or additives containing methanol. Polaris
recommends the use of Carbon Clean Plus.

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

MAXIMUM

REID

VAPOR

AMBIENT

AIR

TEMP

CLASS

PRESSURE

LOW

HIGH

7.0 psi (0.5 bar)

F (16

110

F+

(43

C+)

9.0 psi (0.6 bar)

F (10

110

(43

10.5psi (0.7 bar)



F (36

12.0psi (0.8 bar)



(-1

F (29

13.5psi (0.9 bar)



(-7

F (21

Add 2.45

F for each 1000 ft (305m) above sea level

FUEL

(

GALLONS

)

40:1

RATIO

(

OUNCES

OIL

)

1.45

General Information

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

SAE Tap Drill Sizes

Metric Tap Drill Sizes

Decimal Equivalents

1/64 ................................................................ ............. .0156



............. 1/32 ..................... ...............0312 .... 1 mm= .0394"



3/64 ................................... ...............0469



............. 1/16 ..................... ...............0625



5/64 ................................... ...............0781 .... 2 mm = .0787"



............. 3/32 ..................... ...............0938



7/64 ................................... ...............1094 .... 3 mm =.1181"



............. 1/8......... .1250



9/64 ................................... ...............1406



............. 5/32 ..................... ...............1563 .... 4 mm = .1575"



11/64 ................................. ...............1719



............. 3/16 ..................... ...............1875 .... 5mm= .1969"



13/64 ................................. ...............2031



............. 7/32 ..................... ...............2188



15/64 ................................. ...............2344 .... 6 mm = .2362"



............. 1/4......... .25



17/64 ................................. ...............2656 .... 7 mm = .2756"



............. 9/32 ..................... ...............2813



19/64 ................................. ...............2969



............. 5/16 ..................... ...............3125 .... 8mm= .3150"



21/64 ................................. ...............3281



............. 11/32 .................. ...............3438 .... 9 mm = .3543"



23/64 ................................. ...............3594



............. 3/8......... .375



25/64 ................................. ...............3906 .... 10 mm = .3937"



............. 13/32 ................... ...............4063



27/64 ................................. ...............4219 .... 11 mm =.4331"



............. 7/16...................... ...............4375



29/64 ................................. ...............4531



............. 15/32 ................... ...............4688 .... 12 mm = .4724"



31/64 ................................. ...............4844



............. 1/2......... .5 ....................... ............. 13mm = .5118"



33/64 ................................. ...............5156



............. 17/32 ................... ...............5313



35/64 ................................. ...............5469 .... 14 mm = .5512"



............. 9/16 ..................... ...............5625



37/64 ................................. ...............5781 .... 15 mm = .5906"



............. 19/32 ................... ...............5938



39/64 ................................. ...............6094



............. 5/8......... .625 ................... ............. 16mm=. 6299"



41/64 ................................. ...............6406



............. 21/32 ................... ...............6563 .... 17 mm =.6693"



43/64 ................................. ...............6719



............. 11/16 ................... ...............6875



45/64 ................................. ...............7031 .... 18 mm = .7087"



............. 23/32.................... ...............7188



47/64 ................................. ...............7344 .... 19 mm = .7480"



............. 3/4......... .75



49/64 ................................. ...............7656



............. 25/32 ................... ...............7813 .... 20 mm = .7874"



51/64 ................................. ...............7969



............. 13/16 ................... ...............8125 .... 21 mm =.8268"



53/64 ................................. ...............8281



............. 27/32 ................... ...............8438



55/64 ................................. ...............8594 .... 22 mm = .8661"



............. 7/8......... .875



57/64 ................................. ...............8906 .... 23 mm = .9055"



............. 29/32 ................... ...............9063



59/64 ................................. ...............9219



............. 15/16.................... ...............9375 .... 24 mm = .9449"



61/64 ................................. ...............9531



............. 31/32 ................... ...............9688 .... 25 mm = .9843"



63/64 ................................. ...............9844



............. 1............ 1.0

Thread Size/ Drill Size

Thread Size / Drill Size

#0-80

3/64

1/2-13

27/64

#1-64

1/2-20

29/64

#1-72

9/16-12

31/64

#2-56

9/16-18

33/64

#2-64

5/8-11

17/32

#3-48

5/64

5/8-18

37/64

#3-56

3/4-10

21/32

#4-40

3/4-16

11/16

#4-48

7/8-9

49/64

#5-40

7/8-14

13/16

#5-44

1-8

7/8

#6-32

1-12

59/64

#6-40

1 1/8-7

63/64

#8-32

1 1/8-12

1 3/64

#8-36

1 1/4-7

1 7/64

#10-24

1 1/4-12

1 11/64

#10-32

1 1/2-6

1 11/32

#12-24

1 1/2-12

1 27/64

#12-28

4.6mm

1 3/4-5

1 9/16

1/4-20

1 3/4-12

1 43/64

1/4-28

2-4 1/2

1 25/32

5/16-18

2-12

1 59/64

5/16-24

2 1/4-4 1/2

2 1/32

3/8-16

2 1/2-4

2 1/4

3/8-24

2 3/4-4

2 1/2

7/16-14

3-4

2 3/4

7/16-20

25/64

Tap Size

Drill Size

Decimal



Equivalent

Nearest



Fraction

3x.50

#39

0.0995

3/32

3x.60

3/32

0.0937

3/32

4x.70

#30

0.1285

1/8

4x.75

1/8

0.125

1/8

5x.80

#19

0.166

11/64

5x.90

#20

0.161

5/32

6x1.00

0.196

13/64

7x1.00

16/64

0.234

15/64

8x1.00

0.277

9/32

8x1.25

17/64

0.265

17/64

9x1.00

5/16

0.3125

5/16

9x1.25

5/16

0.3125

5/16

10x1.25

11/32

0.3437

11/32

10x1.50

0.339

11/32

11x1.50

3/8

0.375

3/8

12x1.50

13/32

0.406

13/32

12x1.75

13/32

0.406

13/32

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