2010 2011 2012 2013 Polaris Snowmobile Service Manual 600 800 Rush Pro RMK Assault Indy Switchback
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General Information
1.1
CHAPTER 1
General Information
1
9923839 - 2010-2013 PRO-RIDE Service Manual
© 2012 Polaris Sales Inc.
MODEL SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
2010 600 RUSH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.2
2011 600 RUSH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.4
2011 800 RUSH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.6
2011 800 SWITCHBACK ASSAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.8
2011 800 RMK 155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.10
2011 800 RMK ASSAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.12
2011 800 PRO RMK 155/163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.14
2012 600 RUSH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.16
2012 800 RUSH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.18
2012 800 RUSH PRO-R LE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.20
2012 600 SWITCHBACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.22
2012 800 SWITCHBACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.24
2012 SWITCHBACK ASSAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.26
2012 600 RMK 144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.28
2012 600 RMK 155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.30
2012 600 PRO RMK 155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.32
2012 800 RMK 155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.34
2012 800 RMK ASSAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.36
2012 800 PRO RMK 155/163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.38
2013 600 INDY/INDY SP . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.40
2013 600 RUSH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.42
2013 800 RUSH. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.44
2013 800 RUSH PRO-R LE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.46
2013 600 SWITCHBACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.48
2013 800 SWITCHBACK . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.50
2013 SWITCHBACK ASSAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.52
2013 600 RMK 144 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.54
2013 600 RMK 155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.56
2013 600 PRO RMK 155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.58
2013 800 RMK 155 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.60
2013 800 RMK ASSAULT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.62
2013 800 PRO RMK 155/163 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.64
SNOWMOBILE NUMBER DESIGNATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.66
VEHICLE IDENTIFICATION NUMBER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.66
VIN NUMBER DESIGNATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.66
TUNNEL DECAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.67
PUBLICATION PART NUMBERS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.68
2010 PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.68
2011 PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.68
2012 PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.68
2013 PUBLICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.69
SPECIAL TOOLS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.70
GENERAL REFERENCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.71
STANDARD BOLT TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.71
METRIC BOLT TORQUE SPECIFICATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.71
GASOLINE VOLATILITY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.72
FUEL / OIL PREMIX RATIOS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.72
FUEL RECOMMENDATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.72
SAE TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.73
METRIC TAP DRILL SIZES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.73
DECIMAL EQUIVALENTS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.73
MEASUREMENT CONVERSION CHART . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.74
PISTON WASH / SPARK PLUG READING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1.74
1.2
General Information
9923839 - 2010-2013 PRO-RIDE Service Manual
© 2012 Polaris Sales Inc.
MODEL SPECIFICATIONS
2010 600 RUSH
Model Numbers:
S10BF6KSA / S10BF6KSL / S10BF6KEA
NOTE: OPTIONAL - USE 2 GRAM LIGHTER CLUTCH
WEIGHTS WHEN OPERATING IN PROLONGED
WARM TEMPERATURES (LATE FALL/SPRING
SEASON) TO MAINTAIN PEAK OPERATING RPM.
Engine
Engine Type
Liberty Liquid-Cooled /
Case Reed Induction
Model Number S4202-6044-OP6N
Displacement / # Cylinders 599cc / 2
Bore (inches/mm) 3.04 / 77.25
Stroke (inches/mm) 2.52 / 64
Piston to Cylinder
Clearance (inches/mm)
.0033-.0054 / 0.085-0.137
Installed Ring Gap
(inches / mm)
.014-.020 / 0.356 - 0.508
Operating RPM ±200 8250
Idle RPM 1700
Engagement RPM ±200 3800
Exhaust Valve Spring Purple
Thermostat Opening
Temperature (° F/ ° C)
120 / 49
Fuel Delivery
Type - Number of Fuel
Injectors
DC-CFI - 4
Throttle Body Marking 1203978
Throttle Body Bore 46mm
TPS Voltage @ Idle
(5 VDC +/- .01 Input)
0.95 +/- 0.01 VDC
Fuel Pressure - PSI (bar) 58-60 (4.0-4.1)
Fuel Octane (R+M/2)
10% Ethanol 24 Resistor
Premium/Non-Ethanol
160 Resistor
<91 Octane
(Non-Oxygenated)
OR
87/89/91+
(Up to10% Oxygenated)
91+
(Non-Oxygenated)
Clutch Settings
ALTITUDE
meters
(feet)
DRIVE CLUTCH P2 DRIVEN CLUTCH
Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Gearing
0-600
(0-2000)
10-64
BLACK
120 - 310
7043601
130 - 180
Tabbed
7043515
58/42 - .45
5137176
23:39 - 72
600-1200
(2000-4000)
10-62 22:39 - 72
1200-1800
(4000-6000)
10-60
22:40 - 72
1800-2400
(6000-8000)
10-58
2400-3000
(8000-10,000)
10-56
20:41 - 72
3000-3600
(10,000-12,000)
10A-L
Drive Clutch Bolt Torque: 80 ft-lbs (108Nm)
Re-torque after running engine.
Clutch Settings (Electric Start Models)
ALTITUDE
meters
(feet)
DRIVE CLUTCH P2 DRIVEN CLUTCH
Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Gearing
0-600
(0-2000)
10-64
BLK/GRN
120 - 340
7042083
130 - 180
Tabbed
7043515
58/42 - .45
5137176
23:39 - 72
600-1200
(2000-4000)
10-62 22:39 - 72
1200-1800
(4000-6000)
10-60
22:40 - 72
1800-2400
(6000-8000)
10-58
2400-3000
(8000-10,000)
10-56
20:41 - 72
3000-3600
(10,000-12,000)
10A-L
Drive Clutch Bolt Torque: 80 ft-lbs (108Nm)
Re-torque after running engine.
Track
Width - Inches (cm) 15 (38)
Length - Inches (cm) 120 (304.8)
Pitch
Plies
2.86
2
Lug Height - Inches (cm) 1.25 (3.175) (Ripsaw)
Track tension sag in/cm
with 10 lbs/4.54kg placed
16 in/40cm ahead of rear
idler shaft
7/8 - 1-1/8(2.2 - 2.9cm)
1.3
General Information
1
9923839 - 2010-2013 PRO-RIDE Service Manual
© 2012 Polaris Sales Inc.
NOTE: * = Rider weight in everyday clothing.
** = From full soft (CCW) position.
General
Width (in/cm) 48 / 121.9
Length (in/cm) 108 / 274
Height (in/cm) 46 / 117
Estimated Dry Weight (lb/kg) 459 / 208
Fuel (Gallons / Liters) 11 / 41.6
Oil (Quarts / Liters) 3.4 / 3.3
Cooling System Capacity(Qts/ L) 5.25 / 5.0
Brake Fluid DOT 4
Drive Belt
Part Number
Width (inches / cm)
Side Angle
Circumference (inches / cm)
Center Distance (inches / cm)
3211122
1.460 / 3.7
26°
46.77 / 118.8
11.5 / 29.2
Chaincase
Center Distance (inches)
Top Gear (Stock)
Bottom Gear (Stock)
Chain (Stock)
Gear Lube
Capacity (oz / ml)
Reverse System
7.53
23
39
72
Polaris Synthetic (80W)
9 / 266
PERC
Electrical
Alternator Output
Operating Voltage
Watts @ 13.5 VDC (Total)
13.5 - 14.5 VDC
400
Ignition Timing
18° @1700 RPM
Coolant Temp = 120° F (49° C)
Spark Plug Gap in.(mm) .027 (.70)
Spark Plug NGK BPR9ES
Front Suspension
Suspension Type PRO-RIDE
Shocks
Walker Evans Needle w/Remote
Reservoir
16 Click Compression Adjustable
Factory Setting** = 6
IFS Spring Rate
lbs/in (N/mm)
80 (14)
IFS Spring Installed
Length - Inches (cm)
Preload = 3.75 (9.5)
10.25 (26)
Front Vertical Travel
Inches (cm)
9 (22.9)
Ski Center Distance
Inches (cm)
Setup Width
42.5 (108)
41.52 (105)
Camber Inches (cm) 1.68 0.31 (4.3 .8)
Toe Out Inches (mm) 0 -1/8 (0 - 3)
Rear Suspension
Suspension Type Pro-Ride Progressive
Front Track Shock
(FTS)
Walker Evans w/Remote Reservoir
16 Click Compression Adjustable
Factory Setting** = 2
FTS Spring Rate
lbs/in (N/mm)
120 - 310 (21 - 54.25)
FTS Spring Installed
Length
Inches (cm)
Preload = .75 (1.9)
7.75 (19.7)
Rear Track Shock
(RTS)
Walker Evans Needle
w/Remote Reservoir
16 Click Compression Adjustable
Factory Setting** = 4
Standard RTS Spring
Rider Weight*
120 - 250lbs.
Rate lbs/in (N/mm)
PN: 7043572-385
190 (33.25)
LW RTS Spring
Rider Weight*
90 - 150lbs.
Rate lbs/in (N/mm)
PN: 7041575-385
120 (21)
HD RTS Spring
Rider Weight*
240 - 335+lbs.
Rate lbs/in. (N/mm)
PN: 7043585-385
260 (45.5)
RTS Spring
Rider / Weight Setting
Spring length set to rider weight
using adjustment gauge.
STD Gauge PN: 5253792
LW Gauge PN: 5253854
HD Gauge PN: 5253855
(STD gauge in tool kit. LW and HD
gauges are accessories and should
be ordered when ordering a LW or
HD spring.)
Rider weight adjustment can also be
performed using tape measure and
RTS Spring Guide Table located in
the Steering/Suspension Chapter.
Rear Travel
Inches (cm)
14 (35.6)
1.4
General Information
9923839 - 2010-2013 PRO-RIDE Service Manual
© 2012 Polaris Sales Inc.
2011 600 RUSH
Model Numbers:
600 RUSH
S11BF6NSA / S11BF6NSL / S11BF6NSB / S11BF6NSM
600 RUSH LX
S11BD6NSL / S11BD6NSM
600 RUSH PRO-R
S11BP6NSA / S11BP6NSL / S11PB6NEL / S11BP6NSB
S11BP6NSM / S11BE6NSM
NOTE: OPTIONAL - USE 2 GRAM LIGHTER CLUTCH
WEIGHTS WHEN OPERATING IN PROLONGED
WARM TEMPERATURES (LATE FALL/SPRING
SEASON) TO MAINTAIN PEAK OPERATING RPM.
Engine
Engine Type
Liberty Liquid-Cooled /
Case Reed Induction
Model Number S4215-6044-OO6N
Displacement / # Cylinders 599cc / 2
Bore (inches/mm) 3.04 / 77.25
Stroke (inches/mm) 2.52 / 64
Piston to Cylinder
Clearance (inches/mm)
.0033-.0054 / 0.085-0.137
Installed Ring Gap
(inches / mm)
.017-.025 / 0.450-0.650
Operating RPM ±200 8250
Idle RPM ±200 1700
Engagement RPM ±200 3800
Exhaust Valve Spring Purple
Thermostat Opening
Temperature (° F/ ° C)
120 / 49
Fuel Delivery
Type - Number of Fuel
Injectors
DC-CFI - 4
Throttle Body Marking 1203978
Throttle Body Bore 46mm
TPS Voltage @ Idle
(5 VDC +/- .01 Input)
0.95 +/- 0.01 VDC
Fuel Pressure - PSI (bar) 58-60 (4.0-4.1)
Fuel Octane (R+M/2)
10% Ethanol 24 Resistor
Premium/Non-Ethanol
160 Resistor
<91 Octane
(Non-Oxygenated)
OR
87/89/91+
(Up to10% Oxygenated)
91+
(Non-Oxygenated)
Clutch Settings
ALTITUDE
meters
(feet)
DRIVE CLUTCH P2 DRIVEN CLUTCH
Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Gearing
0-600
(0-2000)
10-64
BLACK
120 - 310
7043681
130 - 180
Tabbed
7043515
58/42 - .45
5137176
23:39 - 72
600-1200
(2000-4000)
10-62 22:39 - 72
1200-1800
(4000-6000)
10-60
22:40 - 72
1800-2400
(6000-8000)
10-58
2400-3000
(8000-10,000)
10-56
20:41 - 72
3000-3600
(10,000-12,000)
10A-L
Drive Clutch Bolt Torque: 80 ft-lbs (108Nm)
Re-torque after running engine.
Clutch Settings (Electric Start Models)
ALTITUDE
meters
(feet)
DRIVE CLUTCH P2 DRIVEN CLUTCH
Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Gearing
0-600
(0-2000)
10-64
BLK/GRN
120 - 340
7042083
130 - 180
Tabbed
7043515
58/42 - .45
5137176
23:39 - 72
600-1200
(2000-4000)
10-62 22:39 - 72
1200-1800
(4000-6000)
10-60
22:40 - 72
1800-2400
(6000-8000)
10-58
2400-3000
(8000-10,000)
10-56
20:41 - 72
3000-3600
(10,000-12,000)
10A-L
Drive Clutch Bolt Torque: 80 ft-lbs (108Nm)
Re-torque after running engine.
Track
Width - Inches (cm) 15 (38)
Length - Inches (cm) 121 (307)
Pitch
Plies
2.52
2
Lug Height - Inches (cm)
RUSH
RUSH PRO-R
1.0 (2.54) (Hacksaw)
1.25 (3.175) (Ripsaw)
Track tension sag in/cm
with 10 lbs/4.54kg placed
16 in/40cm ahead of rear
idler shaft
1/2 - 1.0(1.3 - 2.54cm)
1.5
General Information
1
9923839 - 2010-2013 PRO-RIDE Service Manual
© 2012 Polaris Sales Inc.
NOTE: * = Rider weight in everyday clothing.
** = From full soft (CCW) position.
General
Width (in/cm) 48 / 121.9
Length (in/cm) 108 / 274
Height (in/cm) 46 / 117
Estimated Dry Weight (lb/kg) 469 / 212
Fuel (Gallons / Liters) 11 / 41.6
Oil (Quarts / Liters) 3.4 / 3.3
Cooling System Capacity(Qts/ L) 6 / 5.7
Brake Fluid DOT 4
Drive Belt
Part Number
Width (inches / cm)
Side Angle
Circumference (inches / cm)
Center Distance (inches / cm)
3211122
1.460 / 3.7
26°
46.77 / 118.8
11.5 / 29.2
Chaincase
Center Distance (inches)
Top Gear (Stock)
Bottom Gear (Stock)
Chain (Stock)
Gear Lube
Capacity (oz / ml)
Reverse System
7.53
23
39
72
Polaris Synthetic (80W)
9 / 266
PERC
Electrical
Alternator Output
Operating Voltage
Watts @ 13.5 VDC (Total)
13.5 - 14.5 VDC
400
Ignition Timing
18° @1700 RPM
Coolant Temp = 120° F (49° C)
Spark Plug Gap in.(mm) .027 (.70)
Spark Plug NGK BPR9ES
Front Suspension
Suspension Type PRO-RIDE
Shocks
RUSH
RUSH PRO-R
Fox HPG w/IFP
Walker Evans Needle Piggyback
16 Click Compression Adjustable
Factory Setting** = 6
IFS Spring Rate
lbs/in (N/mm)
100 (17.5)
Spring Preload -
Inches (cm)
4.5 (11.4)
Travel-Inches (cm) 9 (22.9)
Ski Center Distance
Inches (cm)
Setup Width
42.5 (108)
41.52 (105)
Camber Inches (cm) 1.68 0.31 (4.3 .8)
Toe Out Inches (mm) 0 -1/8 (0 - 3)
Rear Suspension
Suspension Type PRO-RIDE Progressive
Front Track Shock
(FTS)
RUSH
RUSH PRO-R
Fox HPG w/IFP
Walker Evans w/Remote Reservoir
16 Click Compression Adjustable
Factory Setting** = 2
FTS Spring Rate
lbs/in (N/mm)
120 - 310 (21 - 54.25)
FTS Spring Installed
Length-Inches (cm)
RUSH Preload
RUSH PRO-R Preload
7.5 (19.05)
1.0 (2.54)
1.0 (2.54)
Rear Track Shock
(RTS)
RUSH
RUSH PRO-R
Fox HPG w/IFP
Walker Evans Needle
w/Remote Reservoir
16 Click Compression Adjustable
Factory Setting** = 4
Standard RTS Spring
Rider Weight*
120 - 250lbs.
Rate lbs/in (N/mm)
PN: 7043572-133
190 (33.25)
LW RTS Spring
Rider Weight*
90 - 150lbs.
Rate lbs/in (N/mm)
PN: 7041575-385
120 (21)
HD RTS Spring
Rider Weight*
240 - 335+lbs.
Rate lbs/in. (N/mm)
PN: 7043585-385
260 (45.5)
RTS Spring
Rider / Weight Setting
Spring length set to rider weight
using adjustment gauge.
STD Gauge PN: 5254748
LW Gauge PN: 5254749
HD Gauge PN: 5254750
(STD gauge in tool kit. LW and HD
gauges are accessories and should
be ordered when ordering a LW or
HD spring.)
Rider weight adjustment can also be
performed using tape measure and
RTS Spring Guide Table located in
the Steering/Suspension Chapter.
Rear Travel
Inches (cm)
14 (35.6)
1.6
General Information
9923839 - 2010-2013 PRO-RIDE Service Manual
© 2012 Polaris Sales Inc.
2011 800 RUSH
Model Numbers:
800 RUSH
S11BF8GSA / S11BF8GSL / S11BF8GSB / S11BF8GSM
800 RUSH LX
S11BD8GSM
800 RUSH PRO-R
S11BP8GSA / S11BP8GSL / S11PB8GEL / S11BP8GSB
S11BP8GSM / S11BP8GEM / S11BE8GSM
NOTE: OPTIONAL - USE 2 GRAM LIGHTER CLUTCH
WEIGHTS WHEN OPERATING IN PROLONGED
WARM TEMPERATURES (LATE FALL/SPRING
SEASON) TO MAINTAIN PEAK OPERATING RPM.
Engine
Engine Type
Liberty Liquid-Cooled /
Case Reed Induction
Model Number S4139-8044-OO8G
Displacement / # Cylinders 794cc / 2
Bore (inches/mm) 3.34 / 85
Stroke (inches/mm) 2.75 / 70
Piston to Cylinder
Clearance (inches/mm)
.004-.0055 / 0.103-0.141
Installed Ring Gap
(inches / mm)
.017-.025 / 0.450-0.650
Operating RPM +0-300 8250
Idle RPM ±200 1700
Engagement RPM ±200 3800
Exhaust Valve Spring Orange
Thermostat Opening
Temperature (° F/ ° C)
120 / 49
Fuel Delivery
Type - Number of Fuel
Injectors
DC-CFI - 2
Throttle Body Marking 1204094
Throttle Body Bore 48mm
TPS Voltage @ Idle
(5 VDC +/- .01 Input)
0.94 +/- 0.01 VDC
Fuel Pressure - PSI (bar) 58-60 (4.0-4.1)
Fuel Octane (R+M/2)
10% Ethanol 24 Resistor
Premium/Non-Ethanol
160 Resistor
<91 Octane
(Non-Oxygenated)
OR
87/89/91+
(Up to10% Oxygenated)
91+
(Non-Oxygenated)
Clutch Settings
ALTITUDE
meters
(feet)
DRIVE CLUTCH DRIVEN CLUTCH
Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Gearing
0-600
(0-2000)
10-66
BLACK
120-310
7043681
BLU/BLK
123-203
7043064
64/42 - .36
5135401
22:36-70
600-1200
(2000-4000)
10-64
1200-1800
(4000-6000)
10-62
1800-2400
(6000-8000)
10-60
BLK/PUR
160-240
7043363
2400-3000
(8000-10,000)
BLACK
140-330
7043829
20:38-70
3000-3600
(10,000-12,000)
10-58
Drive Clutch Bolt Torque: 80 ft-lbs (108Nm)
Re-torque after running engine.
General
Width (in/cm) 48 / 121.9
Length (in/cm) 108 / 274
Height (in/cm) 46 / 117
Estimated Dry Weight (lb/kg) 465 / 211
Fuel (Gallons / Liters) 11 / 41.6
Oil (Quarts / Liters) 3.4 / 3.3
Cooling System
Capacity(Qts/ L)
6 / 5.7
Brake Fluid DOT 4
Drive Belt
Part Number
Width (inches / cm)
Side Angle
Circumference (inches / cm)
Center Distance (inches / cm)
3211115
1.460 / 3.7
26°
46.77 / 118.8
11.5 / 29.2
Chaincase
Center Distance (inches)
Top Gear (Stock)
Bottom Gear (Stock)
Chain (Stock)
Gear Lube
Capacity (oz / ml)
Reverse System
7.53
22
36
70
Polaris Synthetic (80W)
9 / 266
PERC
1.7
General Information
1
9923839 - 2010-2013 PRO-RIDE Service Manual
© 2012 Polaris Sales Inc.
NOTE: * = Rider weight in everyday clothing.
** = From full soft (CCW) position.
Track
Width - Inches (cm) 15 (38)
Length - Inches (cm) 121 (307)
Pitch
Plies
2.52
2
Lug Height - Inches (cm)
RUSH
RUSH PRO-R
1.0 (2.54) (Hacksaw)
1.25 (3.175) (Ripsaw)
Track tension sag in/cm
with 10 lbs/4.54kg placed
16 in/40cm ahead of rear
idler shaft
1/2 - 1.0(1.3 - 2.54cm)
Electrical
Alternator Output
Operating Voltage
Watts @ 13.5 VDC (Total)
13.5 - 14.5 VDC
400
Ignition Timing
18° @1700 RPM
Coolant Temp = 120° F (49° C)
Spark Plug Gap in.(mm) .027 (.70)
Spark Plug NGK BPR9ES
Front Suspension
Suspension Type PRO-RIDE
Shocks
RUSH
RUSH PRO-R
Fox HPG w/IFP
Walker Evans Needle Piggyback
16 Click Compression Adjustable
Factory Setting** = 6
IFS Spring Rate
lbs/in (N/mm)
100 (17.5)
Spring Preload -
Inches (cm)
4.5 (11.4)
Travel-Inches (cm) 9 (22.9)
Ski Center Distance
Inches (cm)
Setup Width
42.5 (108)
41.52 (105)
Camber Inches (cm) 1.68 0.31 (4.3 .8)
Toe Out Inches (mm) 0 -1/8 (0 - 3)
Rear Suspension
Suspension Type PRO-RIDE Progressive
Front Track Shock
(FTS)
RUSH
RUSH PRO-R
Fox HPG w/IFP
Walker Evans w/Remote Reservoir
16 Click Compression Adjustable
Factory Setting** = 2
FTS Spring Rate
lbs/in (N/mm)
120 - 310 (21 - 54.25)
FTS Spring Installed
Length-Inches (cm)
RUSH Preload
RUSH PRO-R Preload
7.5 (19.05)
1.0 (2.54)
1.0 (2.54)
Rear Track Shock
(RTS)
RUSH
RUSH PRO-R
Fox HPG w/IFP
Walker Evans Needle
w/Remote Reservoir
16 Click Compression Adjustable
Factory Setting** = 4
Standard RTS Spring
Rider Weight*
120 - 250lbs.
Rate lbs/in (N/mm)
PN: 7043572-133
190 (33.25)
LW RTS Spring
Rider Weight*
90 - 150lbs.
Rate lbs/in (N/mm)
PN: 7041575-385
120 (21)
HD RTS Spring
Rider Weight*
240 - 335+lbs.
Rate lbs/in. (N/mm)
PN: 7043585-385
260 (45.5)
RTS Spring
Rider / Weight Setting
Spring length set to rider weight
using adjustment gauge.
STD Gauge PN: 5254748
LW Gauge PN: 5254749
HD Gauge PN: 5254750
(STD gauge in tool kit. LW and HD
gauges are accessories and should
be ordered when ordering a LW or
HD spring.)
Rider weight adjustment can also be
performed using tape measure and
RTS Spring Guide Table located in
the Steering/Suspension Chapter.
Rear Travel
Inches (cm)
14 (35.6)
1.8
General Information
9923839 - 2010-2013 PRO-RIDE Service Manual
© 2012 Polaris Sales Inc.
2011 800 Switchback Assault
Model Numbers:
800 Switchback Assault 1.3
S11CW8GSA / S11CW8GSB / S11CW8GEA
S11CW8GEB
800 Switchback Assault 2.0
S11CW8GST
NOTE: OPTIONAL - USE 2 GRAM LIGHTER CLUTCH
WEIGHTS WHEN OPERATING IN PROLONGED
WARM TEMPERATURES (LATE FALL/SPRING
SEASON) TO MAINTAIN PEAK OPERATING RPM.
Engine
Engine Type
Liberty Liquid-Cooled /
Case Reed Induction
Model Number S4229-8044-OO8G
Displacement / # Cylinders 794cc / 2
Bore (inches/mm) 3.34 / 85
Stroke (inches/mm) 2.75 / 70
Piston to Cylinder
Clearance (inches/mm)
.004-.0055 / 0.103-0.141
Installed Ring Gap
(inches / mm)
.017-.025 / 0.450-0.650
Operating RPM +0-300 8250
Idle RPM ±200 1700
Engagement RPM ±200 3800
Exhaust Valve Spring Orange
Thermostat Opening
Temperature (° F/ ° C)
120 / 49
Fuel Delivery
Type - Number of Fuel
Injectors
DC-CFI - 2
Throttle Body Marking 1204094
Throttle Body Bore 48mm
TPS Voltage @ Idle
(5 VDC +/- .01 Input)
0.94 +/- 0.01 VDC
Fuel Pressure - PSI (bar) 58-60 (4.0-4.1)
Fuel Octane (R+M/2)
10% Ethanol 24 Resistor
Premium/Non-Ethanol
160 Resistor
<91 Octane
(Non-Oxygenated)
OR
87/89/91+
(Up to10% Oxygenated)
91+
(Non-Oxygenated)
800 Switchback Assault 1.3 Clutch Settings
ALTITUDE
meters
(feet)
DRIVE CLUTCH DRIVEN CLUTCH
Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Gearing
0-600
(0-2000)
10-66
BLACK
120-310
7043681
BLU/BLK
123-203
7043064
64/42 - .36
5135401
23:39 - 72
600-1200
(2000-4000)
10-64
1200-1800
(4000-6000)
10-62
1800-2400
(6000-8000)
10-60
BLK/PUR
160-240
7043363
21:40 - 72
2400-3000
(8000-10,000)
BLACK
140-330
7043829
20:42 - 72
3000-3600
(10,000-12,000)
10-58
Drive Clutch Bolt Torque: 80 ft-lbs (108Nm)
Re-torque after running engine.
800 Switchback Assault 2.0 Clutch Settings
ALTITUDE
meters
(feet)
DRIVE CLUTCH DRIVEN CLUTCH
Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Gearing
0-600
(0-2000)
10-66
BLACK
120-310
7043681
BLU/BLK
123-203
7043064
64/42 - .36
5135401
20:42 - 72
600-1200
(2000-4000)
10-64
1200-1800
(4000-6000)
10-62
1800-2400
(6000-8000)
10-60
BLK/PUR
160-240
7043363
2400-3000
(8000-10,000)
BLACK
140-330
7043829
3000-3600
(10,000-12,000)
10-58
Drive Clutch Bolt Torque: 80 ft-lbs (108Nm)
Re-torque after running engine.
Track
Width - Inches (cm) 15 (38)
Length - Inches (cm) 144 (365.76)
Pitch
Plies
2.52
2
Lug Height - Inches (cm)
1.3
2.0
1.352 (3.43) (Cobra)
2.0 (5.08) (Series 4)
Track tension sag in/cm
with 10 lbs/4.54kg placed
16 in/40cm ahead of rear
idler shaft
3/8 - 1/2(1 - 1.3cm)
1.9
General Information
1
9923839 - 2010-2013 PRO-RIDE Service Manual
© 2012 Polaris Sales Inc.
General
Width (in/cm) 48 / 121.9
Length (in/cm) 126 / 320
Height (in/cm) 48 / 121.9
Estimated Dry Weight (lb/kg) 457 / 212.7
Fuel (Gallons / Liters) 11.5 / 43.5
Oil (Quarts / Liters) 3.4 / 3.3
Cooling System
Capacity(Qts/ L)
6.0/5.7
Brake Fluid DOT 4
Drive Belt
Part Number
Width (inches / cm)
Side Angle
Circumference (inches / cm)
Center Distance (inches / cm)
3211115
1.460 / 3.7
26°
46.77 / 118.8
11.5 / 29.2
Chaincase
Center Distance (inches)
Top Gear (Stock)
Bottom Gear (Stock)
Chain (Stock)
Gear Lube
Capacity (oz / ml)
Reverse System
7.53
23
39
72
Polaris Synthetic (80W)
9 / 266
PERC
Electrical
Alternator Output
Operating Voltage
Watts @ 13.5 VDC (Total)
13.5 - 14.5 VDC
400
Ignition Timing
18° @1700 RPM
Coolant Temp = 120° F (49° C)
Spark Plug Gap in.(mm) .027 (.70)
Spark Plug NGK BPR9ES
Front Suspension
Suspension Type PRO-RIDE
Shocks
Walker Evans Needle Piggyback
16 Click Compression
Adjustable
Factory Setting** = 6
IFS Spring Rate
lbs/in (N/mm)
100 (17.5)
IFS Spring Installed
Length - Inches (cm)
10.0 (25.4)
Front Vertical Travel
Inches (cm)
9 (22.9)
Ski Center Distance
Inches (cm)
Setup Width
42.5 (108)
41.52 (105)
Camber Inches (cm) 1.68 0.31 (4.3 .8)
Toe Out Inches (mm) 0 -1/8 (0 - 3)
Rear Suspension
Suspension Type Switchback 144 Tipped
Front Track Shock
(FTS)
Walker Evans Piggyback
16 Click Compression
Adjustable
Factory Setting** = 8
FTS Spring Rate
lbs/in (N/mm)
170 (21 - 54.25)
FTS Spring Installed
Length
Inches (cm)
7.25 (18.4)
Rear Track Shock
(RTS)
Walker Evans
w/Remote Reservoir
16 Click Compression
Adjustable
Factory Setting** = 8
Torsion Springs
.359/77°
LH=7041629-329
RH=7041630-329
Rear Travel
Inches (cm)
14.5 (36.8)
1.10
General Information
9923839 - 2010-2013 PRO-RIDE Service Manual
© 2012 Polaris Sales Inc.
2011 800 RMK 155
Model Numbers:
S11CM8GSA / S11CM8GSL / S11CM8GEA
S11CM8GSB / S11CM8GSM
NOTE: OPTIONAL - USE 2 GRAM LIGHTER CLUTCH
WEIGHTS WHEN OPERATING IN PROLONGED
WARM TEMPERATURES (LATE FALL/SPRING
SEASON) TO MAINTAIN PEAK OPERATING RPM.
Engine
Engine Type
Liberty Liquid-Cooled /
Case Reed Induction
Model Number S4229-8044-OO8G
Displacement / # Cylinders 794cc / 2
Bore (inches/mm) 3.34 / 85
Stroke (inches/mm) 2.75 / 70
Piston to Cylinder
Clearance (inches/mm)
.0040-.0055 / 0.103-0.141
Installed Ring Gap
(inches / mm)
.017-.025 / 0.450-0.650
Operating RPM +0-300 8250
Idle RPM ±200 1700
Engagement RPM ±200 3800
Exhaust Valve Spring Orange
Thermostat Opening
Temperature (° F/ ° C)
120 / 49
Fuel Delivery
Type - Number of Fuel
Injectors
DC-CFI - 2
Throttle Body Marking 1204094
Throttle Body Bore 48mm
TPS Voltage @ Idle
(5 VDC +/- .01 Input)
0.94 +/- 0.01 VDC
Fuel Pressure - PSI (bar) 58-60 (4.0-4.1)
Fuel Octane (R+M/2)
10% Ethanol 24 Resistor
Premium/Non-Ethanol
160 Resistor
<91 Octane
(Non-Oxygenated)
OR
87/89/91+
(Up to10% Oxygenated)
91+
(Non-Oxygenated)
Clutch Settings
ALTITUDE
meters
(feet)
DRIVE CLUTCH DRIVEN CLUTCH
Shift
Weight
Clutch
Spring
Clutch
Spring
Driven
Helix
Gearing
0-600
(0-2000)
10-68
BLACK
140-330
7043829
BLACK
155-222
7043063
56/42 - .36
5135403
20:42 - 72
600-1200
(2000-4000)
10-66
1200-1800
(4000-6000)
10-64
1800-2400
(6000-8000)
10-62
2400-3000
(8000-10,000)
10-60
BLK/PUR
160-240
7043363
3000-3600
(10,000-12,000)
10-58
Drive Clutch Bolt Torque: 80 ft-lbs (108Nm)
Re-torque after running engine.
General
Width (in/cm) 46.5 / 118.1
Length (in/cm) 129 / 327.7
Height (in/cm) 51 / 129.5
Estimated Dry Weight (lb/kg) 440 / 199.6
Fuel (Gallons / Liters) 11.5 / 43.5
Oil (Quarts / Liters) 3.4 / 3.3
Cooling System
Capacity(Qts/ L)
5.3/5.0
Brake Fluid DOT 4
Drive Belt
Part Number
Width (inches / cm)
Side Angle
Circumference (inches / cm)
Center Distance (inches / cm)
3211115
1.460 / 3.7
26°
46.77 / 118.8
11.5 / 29.2
Chaincase
Center Distance (inches)
Top Gear (Stock)
Bottom Gear (Stock)
Chain (Stock)
Gear Lube
Capacity (oz / ml)
Reverse System
7.53
20
42
72
Polaris Synthetic (80W)
9 / 266
PERC
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Print one or all pages of your manual
$27.99
This comprehensive manual, spanning 512 pages, is a valuable resource for individuals working with Polaris Snowmobile Models. It covers a wide range of models from 2010 to 2013, including the 600 RUSH, 800 RUSH, SWITCHBACK, RMK, and PRO RMK series.
- General Information
- Periodic Inspection and Adjustments
- Chassis Power Unit
- Powertrain
- Electrical System
- Engine
- Cooling System
- Fuel System
- Specifications
- Troubleshooting
- Many subsections of the above
In addition to the above, the manual includes detailed wiring and circuit diagrams, illustrations, photos, exploded views, step-by-step instructions, diagnostics, and more.
This manual is available in file format and is compatible with all versions of Windows and Mac. It is a valuable resource for both professional mechanics and DIY enthusiasts, providing cost-saving opportunities and empowering users to perform maintenance tasks with ease.
