Snowmobile Polaris 600 RUSH (2010 year). Manual - part 35

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

Updating Digital Wrench

Updates are released for Digital Wrench via the Internet.
The Digital Wrench update website can be found by
accessing the dealer Internet site at:
www.polarisdealers.com.

NOTE:

Only authorized Polaris dealers and

distributors can access the dealer Internet website.

Log on to www.polarisdealers.com.

Locate the “SERVICE AND WARRANTY” drop-down
menu.

Click on “DIGITAL WRENCH UPDATES”.

The next screen is the Digital Wrench portal website.

The following selections can be made on the update
website:

• Home - Digital Wrench Home Page

• Downloads - Listing of current filesets and Digital

Wrench downloadable updates

• Forums - Member generated knowledge base

• Search - Website search engine

• Topics - Vehicle-specific Digital Wrench

information

Locate and click on the version of Digital Wrench
currently running on the PC or laptop.

Locate and click on the update file. Save the file to the
PC or laptop’s desktop.

Locate the update file on the desktop. Double-click
and select “RUN” on the icon to install the update.

Delete the file after performing the update.

NOTE: Delete the update file from the desktop when
finished.

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

Version Identification

Start the Digital Wrench software.

Locate the version ID on the title screen.

The version ID number should match the Digital
Wrench update name.

Special Tests Menu

The SPECIAL TESTS (Tool Box Icon) in Digital Wrench
gives the service technician the following options:

• Vehicle History Information

• Output State Control

• TPS Set Procedure

• Service Report

• ECU Replacement

• Security Functions (2012 Only)

• Engine Controller Reprogramming

• Vehicle Information

• Feature Configuration/Registration

NOTE: Special Tests menu selections will populate
according to vehicle selected.

Vehicle History Information

Selecting the Vehicle History Information option displays
the following information:

• Throttle Position (TPS) history

• Engine RPM history

• Engine run time hours

• Engine overheat occurrences

• Engine overheat misfire protection mode

occurrences

• Engine run time in limp home modes

Service Report

Selecting Service Report from the SPECIAL TESTS
MENU generates a report of all of the current ECU input/
output values, model/calibration/software information,
and diagnostic trouble codes.

Technicians can add the VIN or customers’ name to the
“customer name”’ field and then save the service report as
a .txt file on their laptop/PC.

Clicking on “View Current” will refresh the report
information. Selecting “View Saved” will access any saved
service report .txt files saved on the laptop/PC.

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ECU Replacement

Use the ECU replacement feature whenever installing a
new service ECU on the vehicle. Follow the guided
procedures in Digital Wrench to perform the ECU
replacement procedure.

NOTE: The ECU replacement function initializes the
new service ECU. Service ECUs cannot be reflashed
without first performing this procedure.

The procedure copies the model ID number from the
original ECU, and then copies it to the new service ECU.

IMPORTANT: The procedure cannot be reversed once
the model ID number is copied to the new service
ECU. The service ECU will forever retain the model ID
number copied on it using this procedure.

If communication with the original ECU cannot be
established, Digital Wrench will guide the user through a
manual model ID selection procedure. Pay careful
attention to the model selected when using the manual
procedure.

After completing the ECU replacement procedure, reflash
the ECU with the current ECU calibration file for the
vehicle using the engine controller reprogramming
procedure.

NOTE: ECU replacement only copies the model ID
number to the new service ECU. Vehicle history and
calibration files are not copied over.

Engine Controller Reprogramming (Reflash)

Process Overview

The reprogramming feature is in the Special Tests menu
on the Digital Wrench™ screen. Start Digital Wrench™
and click on the Special Tests menu icon (red tool box). A
technician should be familiar with the process and with
computer operation in general before attempting to
reprogram an ECU.

The Digital Wrench™ Engine Controller Reprogramming
(or “Reflash”) feature allows reprogramming of the ECU
fuel and ignition map. To successfully reprogram the ECU,
an Authorization Key must be obtained by entering a
Request Code in the box provided on the Reflash
Authorization site. The Request Code is automatically
generated by Digital Wrench™ during the reprogramming
process. The Reflash Authorization site is located under
the “Service and Warranty” drop down menu on the
dealer website at: www.polarisdealers.com.

IMPORTANT: Failure to follow the reprogramming
instructions completely and correctly can result in an
engine that does not run! Replacement ECUs are
programmed as “no-start” and require a reflash for
them to work.

Reprogramming (Reflash) Tips:

• BATTERY VOLTAGE: The majority of problems

with reprogramming can be attributed to a low
battery. Be sure the battery voltage (no load) is at
least 13 volts and at least 12.5 volts with the key
‘ON’. Connect a battery charger if necessary to
bring voltage level above minimum. Fully charge
the battery before you attempt to reprogram.

• DEDICATED LAPTOP: Best results are obtained

using a laptop computer that is “dedicated to
Digital Wrench™”. A laptop that is used by a
variety of people and in several applications
around the dealership is more likely to cause a
reprogramming problem than one dedicated to
Digital Wrench™ diagnostics only.

• OBTAINING THE LATEST UPDATE:

Reprogramming updates are provided periodically
and contain the most recent calibrations (see
“Digital Wrench™ Updates”).

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• CLOSE NON-ESSENTIAL PROGRAMS: Polaris

recommends that you DO NOT install non-
essential programs on a Service Department
laptop. Camera detection software, Virus
Scanners, Tool Bars, etc. may clog up memory if
running in the background and make it harder for
the diagnostic software to operate.

• KNOW THE PROCESS: If you are not familiar with

the entire reprogramming process, review the
HELP section of the diagnostic software before
you attempt reprogramming. Click on the ? on the
tool bar or press F11. The information in the on-
line help is the most current and complete
information available. This should be your first
step until you are familiar with the process.

• COMMUNICATION PROBLEMS: If you have had

problems communicating with a vehicle while
performing diagnostic functions, do not attempt
reprogramming until the cause has been identified
and fixed. Check all connections, and be sure
battery voltage is as specified.




Proceed to http://polaris.diagsys.com for
specific information and FAQs on how to
troubleshoot communication problems.

• DON’T DISTURB THE PC: While reprogramming

is in progress, don’t move the mouse and don’t
touch the keyboard. The process only takes a few
minutes, and is best left alone until complete.

NOTE:

New service replacement ECUs are

programmed as “no-start” and must be reflashed for
the engine and fuel injector code.

Verify the most current update is downloaded and
loaded into Digital Wrench.

Connect the communication cables to the
snowmobile connectors.

Start Digital Wrench. Select the model year and
vehicle using the “CHANGE VEHICLE TYPE” button.

Click on the “SPECIAL TESTS” icon.

Click on “ENGINE CONTROLLER
REPROGRAMMING”.

Select the engine model and color of the injectors
installed on the engine. Record the 7 digit injector part
number. Click “CONTINUE”.

NOTE: All fuel injectors on the engine must share
the same color code.




The most-current reflash files will be located at the
top of the list and will not have “SUPERSEDED” in
the file name.




Files with “SUPERSEDED” in the file name denote
older calibrations.

A request code will be generated. Record the code.

Access www.polarisdealers.com. Locate “REFLASH
AUTHORIZATION” under the “SERVICE AND
WARRANTY” drop-down menu.

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