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Snowmobile Polaris 600 RUSH (2010 year). Manual - part 39

4.52

Cleanfire Fuel Injection

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

DC-CFI Troubleshooting Flowchart

Reference the following flowchart for general DC-CFI
troubleshooting techniques.

STEP 1

Preliminary

Checks

DOCUMENT THE BASICS
1. VIN
2. Vehicle Miles
3. Issue(s)
4. Vehicle / Engine Modifications (Non-approved modifications may cause performance/durability issues.)
5. Check unit against Unit Inquiry for any outstanding Service Bulletins or Team Tips
6. Type of fuel in the fuel tank / Fuel Selector Status
The fuel selector jumper wires or resistor plug must be set as outlined below based off of the type of fuel in the tank.

Fuel octane not known, < 91+ octane, or any 87+ octane oxygenated (ethanol, MTBE, etc, blended) fuel = 24 OHM Resistor
91+ octane non-oxygenated (non-ethanol) fuel = 160 OHM Resistor

STEP 2

Using

Digital

Wrench

DIGITAL WRENCH (DW)
1. Is DW the most current version? Check the DW update site (http://polaris.diagsys.com/modules.php?name=Downloads) to review and
download any available updates.
2. Connect DW to the vehicle. Are there any trouble code(s)? Document all of the trouble code(s), both historic and current. Use guided
diagnostics to troubleshoot current trouble code(s). Once repairs are made and trouble code(s) are cleared, do any return? Start the
engine and confirm trouble code(s) to not re-appear. If trouble code(s) re-appear, continue to troubleshoot issue using guided
diagnostics and Service Manual.
3. Review the ECU information for the vehicle. Does the ECU map match the vehicle’s configuration / fuel injector color and part
number? If not, reflash the ECU using the correct color-coded map / part number that matches the fuel injector color / part number
installed on the engine.
4. Is the vehicle subject to any Service Bulletins, or Team Tips where revised ECU reflash files have been made available? If so, verify
the Service Bulletin or Team Tip has been performed if required and the ECU information matches the revised reflash files.

STEP 3

Clutching

CLUTCHING
1. Do the drive clutch weights match what is specified for the elevation where the vehicle is operated? If not, install the specified drive
clutch weights based model specifications for the vehicle located in the appropriate Service Manual or Owner’s Manual Supplement.
2. Inspect drive belt deflection and adjust if required. Replace the belt if it is hour-glassed, shows heavy glazing or severely worn.

STEP 4

Throttle Lever

THROTTLE LEVER FREEPLAY
1. Check the throttle lever freeplay. Too much slack in the throttle cable can cause runability issues.
2. Is the throttle lever freeplay = .010 - .030 inches? If not, reset the freeplay to specification and retest vehicle.

STEP 6

EGT

Sensor

EXHAUST GAS TEMPERATURE SENSOR
1. Using the data display tool in Digital Wrench, monitor the EGT sensor function while the engine is running (vehicle raised off the
ground on a sled lift or track stand) at or above 3,000 RPM.
2. Does the exhaust gas temperature value change with changing throttle lever input after running the engine for 60 seconds at or
above 3,000 RPM?
3. If the EGT value does not change, inspect the sensor wiring and connections. If the wiring and connections are good, replace the
sensor and retest.

STEP 7

Exhaust

System

EXHAUST SYSTEM
1. Check exhaust system for leaks, missing, over-stretched damaged springs, and worn out seals. Replace components as required.
2. Remove the resonator and shake. Replace resonator if shaking reveals loose internal baffle plates.

STEP 8

Ignition

System

IGNITION SYSTEM
1. Insect the spark plug caps and spark plugs. Are the caps worn, oblong, or bent? Replace cap(s) as required.
2. Have the spark plug(s) worn into the top of the cap(s)? If so, replace both the affected spark plug and cap as required.

STEP 9

Exhaust

Valves

EXHAUST VALVES
1. Inspect VES system. Clean valve blades as outlined in the periodic maintenance table. Inspect valve bellows for tears, damage.
2. Inspect the exhaust valve solenoid vent system (discharge hose) for leaks or plugged / kinked hoses. Repair or re-route hoses /
connections as required. Verify outlet hoses is not freezing during operation. Inspect fittings at solenoid are not leaking.
3. Do the exhaust valves move as RPM increases? Test exhaust valve motion by installing a 1 inch piece of clear, fuel vent hose onto
each EV cap nut through the hole in each EV housing. Start the engine and increase the engine speed past 6,000 RPM to check for
proper valve operation.
4. Do both valves move at the same time / rate? If not, inspect one or both EV assemblies. Inspect for torn bellows, worn EV springs
and loose bellows cap nuts. Verify the EV base vent and cylinder holes are clean and free from carbon or heavy residue.

STEP 10

Pistons

PISTONS
1. With the exhaust valve assemblies removed from the cylinders, insert a piston wash light or use a flashlight to inspect the exhaust-
side of the pistons. Is heavy scoring, scratching or ring damage visible?
2. If piston skirt, or ring damage is visible through the exhaust valve slots, the pistons should be replaced and the cylinders inspected
and lightly honed with an Ammco 320 grit (or equivalent) NiCaSil oversize honing stone.

STEP 5

Fuel

System

FUEL SYSTEM
1. Using Digital Wrench, verify the fuel injector supply voltage is 16VDC when the engine is running.
2. Using the appropriate fuel pressure gauge (see Service Manual), verify the fuel pressure when the engine is running is 58 PSI (4BAR).
3. If the fuel pump voltage is good, but the fuel pressure low, replace the fuel filter and recheck fuel pressure.

STEP 11

Engine

ENGINE
1. Perform compression test.
2. Inspect crankshaft index.
3. Verify flywheel key has not sheared (flywheel out of index).

4.53

Cleanfire Fuel Injection

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

Detonation Limit Troubleshooting Flowchart

Reference the troubleshooting table at the beginning of
the chapter and the following flowchart if the ECU

consistently enables the detonation “dET” engine
protection 6,500 RPM limiter.

STEP 1

Preliminary

Checks

DOCUMENT THE BASICS
1. VIN
2. Vehicle Miles
3. Issue(s)
4. Vehicle / Engine Modifications (Non-approved engine/vehicle modifications may cause detonation.)
5. Check unit against Unit Inquiry for any outstanding Service Bulletins or Team Tips
6. Type of fuel in the fuel tank / Fuel Selector Status
The fuel selector resistor plug must be set as outlined below based off of the type of fuel in the tank.

Fuel octane not known, < 91+ octane, or any 87+ octane oxygenated (ethanol, MTBE, etc, blended) fuel = 24 OHM Resistor
91+ octane non-oxygenated (non-ethanol) fuel = 160 OHM Resistor

STEP 2

Using

Digital

Wrench

STEP 4

Clutching

STEP 7

EGT

Sensor

STEP 8

Exhaust

System

EXHAUST SYSTEM
1. Remove aftermarket exhaust pipe(s) and/or non-Polaris tested silencer.
2. Check exhaust system for leaks, missing, over-stretched damaged springs, and worn out seals. Replace components as required.
3. Remove the resonator and shake. Replace resonator if shaking reveals loose internal baffle plates.

STEP 6

Air Leaks

AIR LEAKS
1. Check air box seals, foam, mounting boots, air box-to-hood interface. Verify air box assembly is not cracked/damaged.
2. Inspect throttle body boots for delaminating rubber, or if boots are torn. Verify boots are seated correctly against air box and
throttle body.
3. Does snowmobile have an aftermarket air intake kit installed? Remove the kit and reinstall original components.
4. Inspect engine crankcase seals/base gaskets, etc. for leaks.

STEP 4

Exhaust

Valves

EXHAUST VALVES
1. Inspect the exhaust valve solenoid vent system (discharge hoses) for leaks, plugged, kinked hoses, or icing. Repair or re-route hoses /
connections as required. Verify the outlet hose is not freezing during operation.
2. Start the engine in a well-ventilated area. Raise the track off the ground with a track stand. Rev the engine to clutch engagement
speed. Inspect the VES solenoid outlet hose for exhaust gas discharge. If no gas discharge is seen, the hoses may be plugged,
restricted, or the solenoid circuit is damaged.
3. Do the exhaust valves move as RPM increases? Test exhaust valve motion by installing a 1 inch piece of clear, fuel vent hose onto
each EV cap nut through the hole in each EV housing. Start the engine and increase the engine speed past 6,000 RPM to check for
proper valve operation.
4. Do both valves move at the same time / rate? If not, inspect one or both EV assemblies. Inspect for torn bellows, worn EV springs
and loose bellows cap nuts. Verify the EV base vent and cylinder holes are clean and free from carbon or heavy residue.

STEP 3

Fuel

System

FUEL SYSTEM
1. Check the fuel level in the tank.
2. Using Digital Wrench, verify the fuel injector supply voltage is 16VDC when the engine is running and while operating the snowmobile.
3. Using the appropriate fuel pressure gauge (see Service Manual), verify the fuel pressure when the engine is running and while
operating the snowmobile is 58 PSI (4BAR).
4. Verify fuel filter has been replaced as outlined in the periodic maintenance table. If it has not been replaced initially at 1,000 miles, and
then at 2,000 mile intervals, replace the fuel filter. Re-check fuel pressure.

STEP 5

Detonation Sensor

Fastener Torque

DETONATION SENSOR FASTENER TORQUE
1. The DET sensor fastener must be installed clean and dry and torqued to specification: (168 in.lbs./19 Nm).