Snowmobile Polaris 600 RUSH, 600 RUSH PRO-R, 800 RUSH, 800 RUSH PRO-R (2013 year). Instruction - part 25

102

MAINTENANCE

Clutch System

Drive Belt Deflection

Measure belt deflection with both 
clutches at rest and in their full 
neutral position.

Place a straight edge (1) on the 
belt and apply downward pressure 
while measuring at point 2. This 
measurement should be 1 1/4 
inches (3.2 cm).

Drive Belt Adjustment

1. Loosen the 7/16-inch jam nut on the belt width adjuster.

2. Using a 1/8-inch Allen wrench, turn the set screw inward (clock-

wise) to increase the distance between the sheaves or outward 
(counter-clockwise) to decrease the distance.

3. Tighten the jam nut.

1

2

103

MAINTENANCE

Clutch System

Drive Belt Removal 

NOTICE: Do not attempt to remove the drive belt after operating in reverse. The 

snowmobile must be stopped after forward motion to prevent damage 
to components during belt removal. Rotate the driven clutch counter-
clockwise 1/4 turn by hand to ensure forward engagement before 
attempting to remove the belt.

1. Stop the engine after operating in a forward motion.

2. Turn the ignition key off. Wait for the engine to come to a complete 

stop.

3. Lock the parking brake.

4. Remove the left side panel.

5. Rotate the driven clutch counter-clockwise 1/4 turn by hand to 

ensure forward engagement.

6. Locate the L-wrench in the tool kit. Install the wrench into the open 

threaded hole in the outer sheave of the clutch.

7. Turn the wrench clockwise until the sheaves open far enough to 

remove the belt. If the wrench does not turn readily, rotate the 
driven clutch counter-clockwise an additional 1/4 turn by hand and 
try again.

8. Firmly grasp the belt midway between the clutches and pull upward 

and rearward to remove it.

104

MAINTENANCE

Clutch System

Drive Belt Installation

1. Drop the drive belt over the 

drive clutch and pull back the 
slack. The belt cord line 
should be flush with, or 
slightly above, the outer cir-
cumference of the driven 
clutch sheaves. The belt will 
seat itself in the driven clutch 
during the break-in period. 
Adjust the belt ride-out after 
the break-in period by read-
justing belt deflection.

2. To ensure satisfactory belt life, install belts so they operate in the 

same direction of rotation by positioning the identification numbers 
so that you can read them. If required, separate the sheaves as out-
lined in the belt removal procedures.

3. Turn the driven clutch moveable sheave clockwise while pushing 

inward and forcing the belt down between the sheaves.

4. Hold the belt down between the sheaves and roll the bottom portion 

over the outer clutch sheave. Work the belt to the outer edge of the 
sheave.

5. Rotate the L-wrench to tighten the sheaves. Remove the wrench and 

store in the tool kit.

6. Reinstall the side panel.

7. Break in the new belt. See page 69.

105

MAINTENANCE

Track Maintenance

Track Inspection

WARNING! Broken track rods can cause a rotating track to come off the 
snowmobile, which could cause serious injury or death. Never operate with a 
damaged track. Never rotate a damaged track under power. 

1. Using a hoist, safely lift and 

support the rear of the 
snowmobile off the ground.

2. Rotate the track by hand to 

check for damage.

3. Carefully examine the track 

along the entire length of 
each rod (X). Bend the track 
to check for breakage. 

4. Replace the track if any rod 

damage is found.

Track Lubrication

The slide rail needs snow for lubrication. Excessive wear indicates 
insufficient lubrication. A new rail slide can cause faster heat build-up 
in limited lubrication, resulting in excessive wear. 

WARNING! Operating with insufficient lubrication between the rail slide and 
track guide clips can cause track failure, loss of vehicle control and loss of 
braking ability, which can result in serious injury or death. Avoid operating for 
extended periods on ice and other surfaces that have little or no snow for 
lubrication.

If excessive rail slide wear occurs due to poor snow conditions, addi-
tional wheel kits may be available. See your dealer for more informa-
tion.

Track damage or failure caused by operation on ice or under other poor 
lubrication conditions will void the track warranty.

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