Snowmobile Polaris 600 RUSH, 600 RUSH PRO-R, 800 RUSH, 800 RUSH PRO-R (2013 year). Instruction - part 24

98

MAINTENANCE

Brakes

Bleeding the Hydraulic Brake System

Air in the hydraulic brake system will cause spongy brake lever action. 
Bleed the system before operating the snowmobile.

WARNING! Operating the vehicle with a spongy brake lever can result in loss of 
brakes, which could cause an accident and lead to serious injury or death. 
Never operate the vehicle with a spongy-feeling brake lever.

During the bleeding procedure, keep the brake handle as level as possi-
ble. The reservoir must be in this position to minimize the possibility of 
air entering the system through the reservoir vent.

1. Remove the brake master cylinder reservoir cover and gasket.

2. Fill the master cylinder reservoir to between the MIN and MAX 

marks or 1/4-5/16 inch (.6-.8 cm) below the lip of the reservoir 
opening. Reinstall the gasket and cover.

3. Slip a rubber tube over the ball of the bleeder valve and direct the 

flow of fluid into an approved container.

4. Squeeze the brake lever a full stroke. Then unscrew the bleeder 

valve 3/4 of a turn to release air.

5. Close the bleeder valve and release the brake lever.

6. Repeat steps 4 and 5 until fluid flows from the bleeder valve in a 

solid stream free of air bubbles.

WARNING! Overfilling the master cylinder leaves no room for fluid expansion 
and may cause the brakes to lock, resulting in serious injury or death. Always 
add brake fluid to the fill line as recommended.

7. After bleeding is complete, refill the reservoir to the proper level. 

See page 97. 

8. Reinstall the gasket and cover.

99

MAINTENANCE

Lights

When servicing a halogen lamp, avoid touching the lamp with bare fin-
gers. Oil from your skin leaves a residue, causing a hot spot that will 
shorten the life of the lamp. If fingers do touch a lamp, clean it with 
denatured alcohol.

Headlight Lamp Replacement

1. Remove the wire harness connector from the back of the headlight.

2. Grasp the bulb housing and turn it counter-clockwise to remove the 

bulb.

3. Apply dielectric grease to the socket and install the new bulb. 

Rotate the bulb 1/4 turn clockwise to secure it.

4. Reinstall the connector to the back of the headlight.

Taillight/Brake Light Replacement

The taillight assembly is not serviceable. If the light fails to operate 
properly, replace the entire taillight assembly.

100

MAINTENANCE

Clutch System

Periodically inspect clutch sheaves for damage, wear or belt residue. To 
maintain optimum performance, clean with non-oil based cleaners such 
as isopropyl alcohol. 

WARNING! If you become aware of higher than normal clutch engagement or 
an unusual vibration or shift pattern, see your dealer immediately. Do not 
operate the snowmobile until repairs have been made. 

All clutch maintenance and repairs must be performed by an authorized 
POLARIS dealer. Any unauthorized modifications to clutches, such as 
adding or removing weights, will void the warranty.

NOTICE: The bushings in the weights and rollers of POLARIS clutches are 

made of a material that may be damaged if lubricated. Do not lubri-
cate clutch bushings.

Clutch Alignment Offset

Clutch alignment offset is important for maintaining optimum perfor-
mance. See your dealer for service and adjustments. A special tool is 
required to check for proper alignment.

101

MAINTENANCE

Clutch System

Drive Belt Condition

Periodically check the condition and tension of the drive belt. Inspect 
the belt for signs of excessive wear: frayed edges, missing cogs, cracks 
and excessive looseness. Replace the belt if any of these conditions 
exist. See Drive Belt Troubleshooting on page 124.

Always carry a spare drive 
belt. Store the spare belt in 
the belt clip located under 
the left side of the hood. 
Make sure the o-ring is 
installed over the belt clip.

For improved drive-away during extremely cold temperatures, remove 
the belt and warm it to room temperature. Reinstall it before starting the 
snowmobile.

O-Ring