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Snowmobile Polaris 600 RUSH (2010 year). Manual - part 49

6.12

PVT System

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

Belt Wear / Burn Diagnostics

POSSIBLE CAUSE

SOLUTION

Driving at or about engagement RPM for extended
periods of time in any type of snow condition.

Drive at higher RPM if possible. Gear the machine
down. Make sure belt deflection is at 1 1/4” to achieve
optimum starting ratio.

Cold weather startups

Be patient. Warm up engine at least 5 minutes or until
it readily responds to throttle input. For the quickest
most efficient drive away in extreme cold weather, take
drive belt off machine and bring it in to a warm
environment. Break skis and track loose from the snow.
Engage throttle aggressively for short durations for
initial cold drive away

Towing another machine at or about engagement RPM

When possible, do not go in deep snow when towing
another machine. Use fast, effective throttle to engage
the clutch. Not all machines are intended for pulling
heavy loads or other machines.

Spinning track while vehicle is stuck (high RPM, low
vehicle speed, high ambient temp. Example: 8000
RPM, 10mph actual vehicle speed and 60 m.p.h.
indicated on speedometer.

Lower the gear ratio. Remove windage plates from
driven clutch. If possible, move to better snow
conditions and reduce RPM. Avoid riding in very high
ambient temperatures

Ice and snow piled up between track and tunnel
overnight or after stopping for a long period of time
(enough to re-freeze the snow).

Break loose snow and ice under tunnel. Allow longer
than normal warm-up. Allow belt to warm sufficiently
and increase grip ability on clutch sheaves. Use fast,
effective throttle when engaging clutch.

Poor running engine (Bog, Miss, Backfire, etc.)

Maintain good state of tune including throttle and choke
synchronization. Check for fouled spark plug(s). Check
for foreign material in carburetors. Make sure no water
or ice is present in the fuel tank, lines, or carburetors.

Loading machine on trailer

Use caution when loading machine. Carbide skags may
gouge into trailer and prevent drive train from spinning
freely. Use enough speed to drive completely onto
trailer. If machine cannot be driven completely onto
trailer, it may need to be pulled or pushed to avoid belt
wear / burning.

Clutch malfunction

Check for correct clutch components, or damage on the
clutch

Slow, easy belt engagement - easing on the throttle

Use fast, effective throttle to engage the clutch.

6.13

PVT System

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

Drive Belt Removal - Team Driven

NOTE: Turn the key to the “OFF” position and allow
the engine to come to a complete stop.

Verify the driven clutch is not in reverse. Remove the
LH compartment door panel.

Insert the L wrench, PN 2874857 (A), into the
threaded hole (B) located on the driven clutch, and
turn it clockwise until the clutch sheaves are in the
open position (C).

Remove the drive belt.

Drive Belt Installation - Team Driven

With the L wrench inserted into the threaded hole (B)
and the sheaves in the open position, install the drive
belt.

NOTE: Install belt so that the numbers can be read
correctly on the left side of the machine or in the
direction in which the belt was originally installed.

Remove the wrench. “Wiggle” the belt to remove slack
while removing the wrench.

Close the clutch guard.

Adjusting Belt Deflection - Team Driven

Clutch

Loosen the jam nut.

Using an 1/8



Allen head wrench, turn the stud

counter-clockwise to decrease belt deflection and
clockwise to increase belt deflection.

When the proper belt deflection is achieved torque the
lock nut to specification.

CAUTION

Damage to the driven clutch or L wrench will occur when

attempting to open the driven clutch when the driven

clutch is in the reverse position.

= T

Deflection Set Screw Lock Nut:



90-110 in-lb. (10-12 Nm)

JAM NUT

DEFLECTION STUD

6.14

PVT System

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

Drive Belt Removal - SPA P2

NOTE: Turn the key to the “OFF” position and allow
the engine to come to a complete stop.

Verify the driven clutch is not in reverse. Open the LH
compartment door panel.

Insert the L wrench, PN 2874857, into one of the
threaded holes located on the driven clutch. Turn it
clockwise until the clutch sheaves are in the open
position.

Remove the drive belt.

Drive Belt Installation - SPA P2

With the L wrench inserted into one of the threaded
holes and the sheaves in the open position, install the
drive belt.

NOTE: Install belt so that the numbers can be read
correctly on the left side of the machine or in the
direction in which the belt was originally installed.

Remove the wrench. “Wiggle” the belt to remove slack
while removing the wrench.

Adjusting Belt Deflection - SPA P2

Loosen the deflection screw jam nut.

Using a 1/8 Allen driver, turn the deflection screw in
or out to adjust the distance between the driven clutch
sheaves.

When the proper belt deflection is achieved torque the
lock nut to specification.

CAUTION

Damage to the driven clutch or L wrench will occur when

attempting to open the driven clutch when the driven

clutch is in the reverse position.

THREADED HOLES

= T

Deflection Screw Lock Nut: 110 in-lb (12 Nm)

JAM NUT

DEFLECTION SCREW

6.15

PVT System

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

PVT SYSTEM ADJUSTMENTS

Clutch Alignment/Offset

The drive and driven clutches are offset from each other.
This offset is controlled by the number and thickness of
washers installed on the jackshaft behind the driven
clutch.

Remove drive belt.

Push the driven clutch towards the bulkhead. Install
the alignment tool into the drive clutch and on top of
the driven clutch hub.

NOTE: The PS-47477 offset tool is calibrated with the
correct alignment angle for the respective driven
clutch.




Inspect for broken motor mounts, engine straps or
bulkhead damage if the offset tool reveals major mis-
alignment.

The optimum setup is when the front and rear of the
tool touch the driven clutch. No gap should be present
in the front, and the rear clearance should not exceed
.060" (1.5mm).

NOTE: If the front of the alignment bar does not touch
the driven sheave, the maximum clearance cannot
exceed .025



(.64mm).

Offset/Float Adjustment

Determine direction driven clutch needs to be
adjusted.

Remove driven clutch retaining bolt, and remove
driven clutch.

With one 16 GA. bushing installed, add or remove
offset washers from behind the driven clutch to set the
proper offset.

After adjusting the offset, add or remove shim
washers from behind the driven clutch bolt and
washer to provide a .060" (.1.5mm) driven clutch float
on the jackshaft.

AR = As Required

TOOL

PART

NUMBER

APPLICATION

PS-47477

Light Weight (LWT) Team Driven / P2

Driven Clutch Offset/Shim Washers

Offset Washers

16 Gauge Bushing=7556509 (QTY.1)

.023” = 7555917 (AR)
.120” = 7555864 (AR)

Float Washers

.065" = 7555806 (AR)
.105" = 7555832 (AR)

CAUTION

Always verify the driven clutch floats on the jackshaft.

The jackshaft bearing will fail from side-loading if the

driven clutch is not allowed to float.

0” - .060”

TOUCHING

(PN: PS-46998 Shown)

PUSH CLUTCH

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