Snowmobile Polaris 600 RUSH (2010 year). Manual - part 38

4.48

Cleanfire Fuel Injection

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

VARIABLE EXHAUST SYSTEM (VES)

Overview

The Polaris VES system uses exhaust valves



(1 valve per cylinder) to control the exhaust port height.
The valves are actuated by controlling cylinder pressure
with a solenoid, bellows, and a series of vent hoses.

The solenoid is powered by 12 VDC and turned on and off
by the engine control unit (ECU).

When the solenoid is powered (ON), the VES vent paths
are open allowing cylinder pressure to vent to
atmosphere, and the guillotine valves remain in the closed
(down) position.

When the solenoid is OFF, the vent path(s) are closed.
Cylinder gas pressure builds within the exhaust valve
housings beneath the bellows. Once the cylinder gas
pressure pushing on the bellows overcomes the spring
pressure, the bellows will inflate, lifting the guillotine
valves from the closed (down) position.

The ECU uses engine RPM and throttle position (TPS) as
the primary variable exhaust system solenoid control
signals. In general, the ECU will close the solenoid at
100% wide open throttle (WOT) at approximately 6500-
6900 RPM.

When troubleshooting the variable exhaust system, follow
these guidelines:

• Use the recommended oil. Polaris recommends

VES Gold Plus engine oil for maximum VES
performance.

• Never mix different brands of oil.

• Follow the recommended valve periodic

maintenance schedule.

• Do not use harsh abrasives or sharp tools when

cleaning the valves. Small abrasions and nicks
can create pockets of carbon formation.

• Replace rusted/corroded springs.

• Inspect the bellows and replace if distorted,

stretched, or torn.

• Replace the housing gasket each time the housing

is removed from the cylinder. Do not modify the
gasket in anyway.

• Inspect the vent hoses and fittings for leaks.

Remove and apply thread sealant to fittings that
appear to be leaking oil/exhaust gases.

• Verify all hose clamps are tight.

• Use a Mity Vac™ hand pump to test the solenoid

function. The solenoid must hold pressure and not
leak when not powered. The solenoid must vent
when powered with 12VDC.

CAUTION

Do not plug the vent hoses or tamper with solenoid.

Severe engine damage may occur.

4.49

Cleanfire Fuel Injection

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

ELECTRONIC REVERSE (PERC)

Overview

The operation of the electronic reverse system is achieved
by automatically reversing the engine rotation with a push
of a button. When in reverse, an indicator light will flash,
indicating the engine is in the reverse mode. The design
of the clutches are matched to the specifications that will
allow the backwards rotation of the engine to move the
sled in reverse. To get back to forward is as easy as
pushing the button again.

Operation

Ensure that the vehicle is stopped and the engine is
warmed up and running at idle.

NOTE: The system will only engage in reverse if the
engine is below 4000 RPM. If engine is above 4000
RPM the system can not be activated.

Ensure that the path behind you is clear.

Push and hold the yellow reverse button on the left
hand control for 1 second and then release the button.
The reverse light on the instrument panel will flash
when engine is in reverse motion.

NOTE: The engine will automatically reduce RPM
and it will reverse the rotation of the engine when the
RPM is at the lowest RPM point.

Ensure that the path behind you is clear.

Slowly apply throttle until the sled starts to move in
reverse, and carefully direct the sled in the direction
that you want.

NOTE: Maximum RPM in reverse is 6000 RPM.

NOTE: If the engine stops running or is shut off
while in reverse. The engine will start in forward
gear.

FORWARD OPERATION

If unit was operated in reverse, ensure that the path
ahead is clear, and push an hold the reverse button
for 1 second and then release the button. The engine
will now automatically change direction form reverse
to forward and the reverse light on the instrument
panel will stop flashing.

NOTE: When servicing clutches, ensure that the
vehicle is in forward gear. If not damage to the
driven clutch may occur when removing the belt.

WARNING

Reverse operation, even at low speeds, may cause

loss of control, resulting in serious injury or death. To

avoid loss of control, always:

LOOK BEHIND BEFORE AND WHILE BACKING.

AVOID SHARP TURNS.

SHIFT TO OR FROM REVERSE ONLY WHEN

STOPPED.

APPLY THROTTLE SLOWLY.

CAUTION

To avoid personal injury and/or engine damage, do not
operate the electric start or recoil while engine is
running.

4.50

Cleanfire Fuel Injection

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

Altitude Setting

If your engine is carbureted, you can adjust the elevation
setting of the Polaris electric reverse control (PERC). If
your engine is a Cleanfire system, this is automatically
done through the engine controller unit (ECU), and you do
not need to do any setting.

At higher elevations over 6000 feet (1829m), the engine
requires a different ignition RPM setting to improve the
operation of the reverse system.

To set the altitude settings:

With the engine running, push and hold the reverse
button for 5 - 6 seconds and then release the button.

The reverse light will flash rapidly on the instrument
panel.

You have now set the PERC system to the higher
elevation setting.

To go back to the low elevation setting repeat step 1.
The reverse light will flash slowly indicating that the
system is now in the lower elevation setting.

NOTE: The elevation setting will be set in the
memory (engine running or not) until it is changed.

Important Notes

• Max RPM for shifting into reverse = 4000 RPM

• Max RPM for operating in reverse = 6000 RPM

• Engine must first reach 900 RPM at start up before

the reverse system can be used. The system
works between 900 and 4000 RPM.

• If the button is pushed above 4000 RPM the

system is bypassed and nothing will happen.

• Flashing light on the instrument panel indicates

that the system is in reverse. On carbureted units
a slow flash indicates that the system is set for low
elevation, and a fast flash indicates the system is
set up for high elevation. Push and hold the
reverse button for longer than 5 seconds to toggle
back and forth from high and low elevation
settings. On Cleanfire units this is automatically
done through the engine controller unit (ECU).

• Elevation above 6000 ft (1829m) requires a

different timing curve to eliminate a “kick-back”
effect.

• If engine is shut off or dies in forward or reverse

gear, the engine when started will automatically be
in forward gear.

• When servicing clutches, ensure that the vehicle is

in the forward gear.

• On DC-CFI models the PERC system will not

operate if the TPS is out of adjustment or the 5
tooth CPS signal is interrupted or broken.

4.51

Cleanfire Fuel Injection

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

TROUBLESHOOTING

Engine Will Not Start

• Is the key inserted in key switch and turned to

RUN?

• Is the safety slap switch pulled up?

• Is the throttle lever free play set to specification?

• Is there fuel in the fuel tank?

• Is the fuel tank vent/vac. hose plugged or

malfunctioning? Remove fuel tank cap and try to
start engine.

• Are the spark plugs fouled? Replace with new

spark plugs.

• Is there spark at the spark plugs? Test with spark

plug tester.

• Inspect wire harness connectors. Are connectors

disconnected? Are there any broken wires?

• Is the throttle plate gap set to specification?

• Is there fuel pressure? Test using fuel pressure

gauge. Determine if fuel filter requires
replacement.

• Inspect the stator using multitester and/or Digital

Wrench. Are the fuel injectors receiving 16 VDC?
Is the fuel pump receiving VDC power when
pulling recoil?

• Are there any diagnostic trouble codes? Use

Digital Wrench to view trouble codes and perform
guided diagnostics.

• Is the engine mechanically sound? Check cylinder

compression, piston condition, etc.

Engine Starts - Won’t Idle/Stalls

• Is the throttle lever free play set to specification?

• is the fuel tank vent/vac. hose plugged or

malfunctioning? Remove fuel tank cap and test.

• Are the spark plugs fouled? Replace with new

spark plugs.

• Inspect wire harness connectors. Are connectors

disconnected? Are there any broken wires?

• Is there fuel pressure? Test using fuel pressure

gauge. Determine if fuel filter requires
replacement.

• Are there any diagnostic trouble codes? Use

Digital Wrench to view trouble codes and perform
guided diagnostics.

• Is the throttle plate gap/TPS set to specification?

Poor Performance

• Fuel quality. Use recommended fuel (91 octane

minimum).

• Ethanol/Non-ethanol fuel resistor plug. Is the

correct fuel selector plug connected for the type of
fuel in the tank?

• Are the spark plugs fouled? Correct gap set?

• Is the fuel pressure correct at idle and during

operation?

• Fuel filter. Has the fuel filter been serviced as part

of periodic maintenance?

• VES system. Have the valves, and bases been

serviced/cleaned as part of periodic maintenance?

• VES system. Are the hoses loose, damaged or

plugged/frozen?

• Inspect fuel injector power. Are injectors receiving

16 VDC during operation?

• Is the engine mechanically sound? Perform a

compression check on both cylinders. Are the
results within 10% of each other?

• Inspect piston skirts through exhaust ports. Is

there any scuffing, ring damage, etc.?

• Inspect the exhaust system. Are there any leaks,

missing springs, or damaged exhaust seals?

• Driveline. Inspect the driveline for damage. Set the

track tension to specification. Is the track too tight
or missing lugs? Is the gear ratio correct for
desired riding style?

• Inspect the drive, driven clutches, and drive belt.

Replace worn or damaged parts. Clean clutch
sheaves, and set belt deflection.

• Are there any diagnostic trouble codes (DTCs).

Use Digital Wrench to retrieve any codes.

• Reference CFI Troubleshooting Flowchart

• Is detonation occurring and/or detonation engine

RPM limit occurring? Reference Detonation
Troubleshooting Flowchart/checklist.

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