Snowmobile Polaris 600 RUSH (2010 year). Instruction - part 2

 

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Snowmobile Polaris 600 RUSH (2010 year). Instruction - part 2

 

 

1.6

General Information

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

© 2011 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

7043342

20:38-70

3000-3600

(10,000-12,000)

10-58

Drive Clutch Bolt Torque: 80 lb.ft. (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

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

© 2011 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

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

© 2011 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

7043342

20:42 - 72

3000-3600

(10,000-12,000)

10-58

Drive Clutch Bolt Torque: 80 lb.ft. (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

7043342

3000-3600

(10,000-12,000)

10-58

Drive Clutch Bolt Torque: 80 lb.ft. (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

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

© 2011 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)

 

 

 

 

 

 

 

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