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Snowmobile Polaris 600 RUSH (2010 year). Manual - part 31

4.20

Cleanfire Fuel Injection

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

Fuel System Assembly

RETURN HOSE w/SCHRADER VALVE

SUPPLY HOSE w/FILTER

FILTER BRACKET

THROTTLE POSITION SENSOR (TPS)

CYLINDER (PORT) INJECTORS

CRANKCASE INJECTORS

P-CLAMP (INSTALLED UNDER FILTER BRACKET)

= T

A: 9 ft-lb (12 Nm)



B: 1.5 ft-lb (2 Nm) Position p-clamp behind bracket.

4.21

Cleanfire Fuel Injection

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

DC-CFI-2 FUEL INJECTORS/FUEL
RAIL

Fuel Injectors/Assembly

DC-CFI-2 engines feature a dual fuel injector/wiring
harness assembly. Fuel injector replacement requires
removing both fuel injectors/harness and installing a new
assembly. Fuel injectors are not supplied individually.
Harness cutting and splicing is not required.

When replacing a fuel injector assembly, match the fuel
injector color code with the service part number listed in
the table below. If replacing a fuel injector assembly with
one of a different color code, the ECU must be flashed with
the new color-coded ECU map.

NOTE: In addition to the fuel injector o-rings, an
isolator o-ring (2011) or bushing (2012) is installed
inside each cylinder fuel injector bore.

NOTE: 4013046-015 (RED) fuel injectors are no
longer available. Order and install either YELLOW or
BLUE injectors. After installing new injectors,
reflash the ECU to match the new fuel injector color
code.

CAUTION

2011 and 2012 fuel injectors are different and not

interchangeable. Severe engine damage will occur if the

incorrect fuel injectors are installed.

O-RINGS (7.52MM ID)

2011 FUEL INJECTORS w/HARNESS

ISOLATOR O-RING (12.4MM ID)

O-RING (BROWN)

2012 FUEL INJECTORS w/HARNESS

GREEN BUSHING

O-RING (BLACK)

2011 800 DC-CFI-2 INJECTOR KITS

INJECTOR

KITS

COLOR

4013046-053

Yellow

4013046-027

Blue

2012 600/800 DC-CFI-2 INJECTOR KITS

INJECTOR

KITS

COLOR

4013258-053

Yellow

4013258-027

Blue

4013258-015

Red

4.22

Cleanfire Fuel Injection

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

Fuel Rail Bleeding / Pressure Testing

DC-CFI-2 PRO-RIDE models feature a Schrader valve
located on the fuel pump that can be used to bleed the fuel
system pressure and observe fuel system pressure when
using the fuel pressure gauge and specified adapter.

Fuel Pressure Gauge (PU-43506-A)

Fuel Pressure Gauge Adapters

• A = 314249 (.305-32 shallow core fitting/adapter

supplied with PU-43506-A Fuel Pressure Gauge)

• B = PS-48617 (.305-32 deep core fitting)

• C = PS-48762 (7/16-20 fitting)

Select the appropriate adapter.

Connect the adaptor to the fuel return hose Schrader
valve.

Connect the adapter to the fuel pressure/bleed tool
gauge.

To observe running fuel system pressure, start the
engine and compare reading to the specification.

NOTE: Observe pressure reading at idle and while
operating the vehicle.

To bleed the fuel system pressure after the engine is
stopped, place the tool’s bleed hose into an
appropriate fuel handling container. Open the valve to
release the pressure and drain residual fuel.

Close the valve, then remove the gauge and adapter
from the fuel hose Schrader valve. Replace the
Schrader valve dust cap.

Fuel Pressure Gauge/Adapters

MODEL

ADAPTERS

GAUGE

BLEED

TOOL

DC-CFI-2



PRO-RIDE



PS-48762



(7/16-20 fitting)

PU-43506-A

SCHRADER VALVE

PU-43506-A

CONNECT TO ADAPTER

= In. / mm.

Fuel System Pressure:



58-60 (4.0-4.1)

4.23

Cleanfire Fuel Injection

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

Disconnect Fittings

The fuel hoses feature disconnect fittings that require
special tools to remove.

The fuel line disconnect tool kit, PS-47152, supplies one
5/16



and one 3/8



quick disconnect tool. These tools are

also commercially available at local auto parts stores.

To disconnect a fuel hose from the fuel pump, or fuel
rail, insert the tapered end of either the 5/16



or 3/8



tool into the female housing.

Push the tool into the housing to release the spring
clamps. Carefully separate the hose from the
connection.

Reconnect the fuel hoses by coating each hose end
with a light film of two stroke engine oil.

Carefully install the male end of the hose into the
center of the female housing. Firmly push the hoses
together until the male nozzle fully seats behind the
spring tabs and an audible “click” is heard.

Grasp both hoses and gently pull to verify positive
engagement.

Fuel Rail Microdampers

The DC-CFI-2 fuel rail assembly contains two fuel
pressure microdampers. The microdampers suppress
fuel pressure pulses that occur when each fuel injector is
activated.

The microdampers are considered “life of engine”
components and servicing is not recommended. If a
microdamper is removed, apply a light film of two-stroke
engine oil to the o-ring during installation.

Torque clamp fasteners to specification.

NOTE: A threaded plug is located on the MAG end of
rail. Do not remove plug.

PS-47152

3/8

 DISCONNECT TOOL

= T

A: 3.3 ft-lb (4.5 Nm)

FUEL RAIL

MICRODAMPERS w/O-RINGS

CLAMPS

PLUG

FUEL SUPPLY

FUEL RETURN

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