Snowmobile Polaris 600 RUSH (2010 year). Manual - part 36

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

© 2011 Polaris Sales Inc.

9.

Enter the REQUEST CODE generated by Digital 
Wrench into the information box.

10. After entering the REQUEST CODE, click 

“CONTINUE”.

11. The next screen asks for the following information:

• Desired Reflash File

• Vehicle VIN

• Customer Name, Address, Zip Code

12. After entering the required information, click 

“CONTINUE”.

13. If all of the information was accurate, the website will 

generate and AUTHORIZATION CODE.

14. Copy the code, and then enter the code into the 

AUTHORIZATION box in Digital Wrench. Click 
“CONTINUE”.

15. The reflash process will begin. Verify all connections 

are properly made. Do not touch anything during the 
process.

16. Verify the reflash was a success by comparing the 

software ID number listed under the “CUSTOMER 
AND VEHICLE IDENTIFICATION” button with the 
number recorded in step 6.

NOTE: If security function was enabled on vehicle 
prior to replacing the ECU and/or performing the 
engine controller reprogramming, the Security 
Enable procedure will have to be completed to 
activate security in the ECU.

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

© 2011 Polaris Sales Inc.

Digital Wrench Data Grid Screenshots

2010 RUSH 600 - Engine at Idle (75° F shop room 
temperature/1,060 ft. ASL)

The data grid can display numerous sensor/switch inputs 
and outputs. Not all are shown in the screenshots above. 
Use the (+) and (-) button to add and remove data 
parameters.

Always verify the reading against known information. 
Some of the items to look for include:

• Is the barometric pressure, intake air temperature, 

and engine coolant temperature accurate?

• Is the TPS voltage (at idle) 0.95 +/- .01 VDC?

• Does the TPS voltage transition smoothly when 

the throttle lever is pushed?

• Is the Injector/ignition voltage 15.5-16.5 VDC?

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

© 2011 Polaris Sales Inc.

THROTTLE POSITION SENSOR

Throttle Position Sensor (TPS) Overview

The Throttle Position Sensor (TPS) is a 5 VDC potentiometer (variable resistance) type sensor mounted to the PTO side 
of the throttle body. The internal components of the sensor are connected to the throttle shaft. The TPS output signal 
changes as the throttle plates are opened and closed by the operator. The ECU uses this signal to determine the position 
of the throttle plates.

The TPS is set at the factory based on a throttle body idle air gap flow specification. Adjustments should only be 
performed when:

• TPS is replaced

• TPS or throttle body is mis-adjusted

• Troubleshooting erratic or inconsistent engine idle, and/or engine performance

NOTE:  Follow these guidelines whenever working with the TPS:

• Use Digital Wrench when checking the TPS voltage. Do not use any other diagnostic tool.

• Disconnect throttle cable from the throttle lever. If the TPS idle voltage changes, the throttle cable is too tight. 

Readjust throttle cable.

• Verify the throttle cable is not pulling on the throttle plate cam. Turn the throttle cable in line adjuster clockwise to 

loosen the cable. If the cable continues to pull on the throttle plate cam, readjust the throttle cable threaded 
barrel on the throttle body.

• All engine management sensors/switches must be connected to obtain accurate TPS voltage readings.

• Use a fully charged 12VDC battery to power the engine management system

CAUTION

The throttle position sensor (TPS) is set at the time of throttle body manufacture. TPS adjustments should only be 

made if the TPS was loosened, repositioned, or replaced.

Any adjustments made to the idle air gap screw, TPS sensor, or throttle synchronization screw should only be 

performed when directed to so by the Digital Wrench Diagnostic Software.

TPS

THROTTLE BODY

ENGINE

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

© 2011 Polaris Sales Inc.

TPS Tests

Two tests can be performed to quickly determine if further testing is required.

TEST 1: TPS Idle Voltage

1.

Connect Digital Wrench to the vehicle. Confirm the throttle lever free play is set to specification, and the throttle 
cable is not pulling on the throttle plate cam.

2.

Click on the DATA GRID ICON to view the current sensor readings.

3.

Locate the TPS VOLTAGE reading and compare it to the specification for the vehicle. Verify SENSOR REFERENCE 
VOLTAGE is 4.9-5.0 VDC.

TEST 2: TPS Signal Sweep

Utilize the sensor graph function to view the TPS voltage return signal voltage as a line graph.

1.

Slowly move the throttle lever in and out. The return signal line should change without any erratic jumps or gaps.

2.

If erratic jumps or gaps are encountered, inspect the wiring, and connector pins at the sensor and ECU connector.

3.

If no wiring problems are found, inspect the TPS to verify it is securely mounted to the throttle body. If loose, it will 
have to be readjusted.

4.

Replace the TPS if steps 3 and 4 do not resolve the issue.

TPS Idle Base Setting Voltage

MODEL

SPECIFICATION

600 DC-CFI Engine

.94-.96 VDC

800 DC-CFI Engine

.93-.95 VDC