Snowmobile Polaris 600 RUSH (2010 year). Instruction - part 27

 

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Snowmobile Polaris 600 RUSH (2010 year). Instruction - part 27

 

 

4.4

Cleanfire Fuel Injection

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

© 2011 Polaris Sales Inc.

ENGINE PROTECTION FEATURES

Engine Temperature RPM Limit

The ECU will illuminate the instrument cluster engine hot 
LED when it determines the engine is overheating. The 
ECU will flash the hot LED and enable a RPM misfire if it 
determines continued engine operation will cause serious 
engine damage. The ECU makes this determination 
based on current engine coolant temp, engine RPM, and 
throttle position.

NOTE:  * = Only minimum (idle) and maximum (WOT) 
parameters listed. 

The driver must take immediate action to cool the engine 
once the hot LED is illuminated. Drive the snowmobile in 
loose, un-packed snow to cool the engine. If trail 
conditions are poor, turn the engine off and allow it to cool.

When the engine is cool, check the coolant level in the 
surge bottle (reservoir). Only add coolant when the engine 
is sufficiently cooled. Never add coolant when engine is 
hot.

If the snowmobile must be operated while the indicator 
LED is illuminated, drive slowly and stop the engine 
frequently to allow it to cool down.

Continued engine operation with the engine hot LED 
illuminated may cause serious engine damage. If the ECU 
determines serious engine damage may occur, the hot 
lamp will flash and an engine RPM misfire will be enabled. 

The ECU will also register and accumulate (count the 
number of occurrences) DTCs (110/0 or 110/16) if the 
engine overheats or goes into the overheat misfire mode.

Engine Overheating Troubleshooting

If the hot lamp is illuminated or flashing with the engine 
overheat RPM misfire enabled, reference the table below.

Engine Temperature Limit Modes

MODEL

HOT

 

LAMP

MODE

THRESHOLD

*

600/800

DC-CFI 2/4

Hot Lamp ON

Hot Lamp Illuminates:

Idle = 230° F/110° C

WOT = 185° F/85° C

Hot Lamp 
FLASH 

Hot Lamp Flashes

RPM Misfire at:

Idle = 239° F/115° C

WOT = 208° F/98° C

CAUSE

 

OF

 

OVERHEAT

SOLUTION

Riding in poor conditions

Ride snowmobile on good 
snow (loose, fresh, un-packed 
snow)

Low coolant level

Allow engine to cool. Refill 
coolant surge bottle to COLD 
line

Incorrect coolant/mix ratio

Use 60/40 (propylene glycol/
distilled water mixture

Air in cooling system

Bleed cooling system

Heat exchangers/hoses 
damaged or plugged

Inspect components for 
damage, hose kinks, etc.

Thermostat malfunctioning

Inspect thermostat for proper 
operation

Water pump malfunctioning

Inspect coolant flow

Cylinder base gaskets/o-rings 
damaged.

Pressure test cooling system. 
Verify system holds pressure/
pressure does not leak into 
cylinders

Snow flap damaged or 
removed

Inspect rear snow flap 
assembly. Verify flap(s) are not 
damaged or missing

Vehicle use

Verify vehicle is not overloaded 
during operation (high load/
high engine RPM and low 
ground speed)

Track condition/tension

Verify track is not missing lugs. 
Set correct track tension

4.5

Cleanfire Fuel Injection

4

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

© 2011 Polaris Sales Inc.

Detonation Protection (DET)/RPM Limit

When DET is sensing and taking action to reduce 
detonation, the driver may notice a drop in engine RPM 
and/or reduced performance.

The ECU will illuminate the instrument cluster check 
engine LED and display “dET” on the LCD screen 
whenever the DET system is active.

If the ECU determines the detonation cannot be controlled 
by normal means and further operation may cause engine 
damage, the check engine LED will flash, the instrument 
cluster will display “dET”, and the ECU will limit the 
maximum engine speed to 6,500 RPM. The RPM limit will 
remain active until the driver turns off and restarts the 
engine.

If the detonation RPM limit occurs, a diagnostic trouble 
code (DTC) will be registered. Digital Wrench will display 
one of the following codes: 1352/0 (P1336), 1352/16 
(P2336), 1353/0 (P1337), or 1353/16 (P2337).

DET Troubleshooting

If the check engine LED is illuminated and/or flashing with 
“dET” displayed on the instrument cluster, reference the 
following table.

NOTE: A DET Troubleshooting flowchart is located 
at the end of the chapter.

DET Protection RPM Limit Modes

MODEL

CHECK

 

ENGINE

 

LED

/

INSTRUMENT

 

CLUSTER

 

MODE

RPM

 

LIMIT

600/800

DC-CFI-2/4

Check engine 

LED illuminated/ 

“dET” displayed 

on LCD

Driver may notice 

slight drop in engine 

RPM/power

Check engine 

LED flashing/ 

“dET” displayed 

on LCD

6,500 RPM Misfire

Turn off engine to 

reset.

CAUSE

 

OF

 

DET

 

ACTIVATION

SOLUTION

Low fuel/no fuel in tank

Refill tank with recommended 
fuel

Incorrect ethanol/non-ethanol 
fuel resistor installed

Verify correct fuel selector 
resistor installed for fuel type in 
tank

Poor quality fuel/water in fuel

Replace with higher quality 
fuel. Recommended 91 octane 
minimum

Alcohol-based fuel additives 
used with ethanol fuel

Do not use deicers or additives 
that contain any form of alcohol 
when using ethanol-blended 
fuel

Restricted fuel filter

Replace fuel filter

Low fuel pressure

Verify fuel pressure is 58 psi (4 
BAR) at idle and while riding

Low fuel injector voltage

Verify fuel injection circuit is at 
16 VDC when engine is 
running

Faulty/plugged fuel injector

Use Digital Wrench to 
troubleshoot

VES system malfunctioning

Verify valves are not stuck 
open, vent hoses are not 
frozen or plugged

Knock sensor malfunctioning

Verify knock sensor screw 
torque is set to specification

Air leaks

Verify air intake system is 
sealed. Check throttle body 
boots for cracks/tears/loose 
parts. Remove after-market air 
intake system.

Engine/exhaust modifications Remove modifications

Engine coolant temperature 
high

Check cooling system. Ride 
snowmobile on loose, un-
packed snow

Mechanical failure

Verify crankcase seals are 
good (not leaking). Verify 
engine in good condition. 
Check spark plugs.

4.6

Cleanfire Fuel Injection

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

© 2011 Polaris Sales Inc.

CLEANFIRE™ FUEL INJECTION

System Overview

System components include:

• ECU: The ECU controls the ignition / fuel injection 

angle, chassis/battery relays, and supplies the 
MFD gauge with tachometer, water temperature, 
PERC, HOT, DET, and diagnostic information.

• Stator: Stator lighting charge coil split into two 

independent circuits; one for DC power (Chassis) 
and one for AC power (Lighting).

• Flywheel: Flywheel is forged. Fan cover is 

removed from flywheel.

• CFI Regulator / Rectifier: Supplies power to the 

ECU, fuel pump “boost power”, MFD, LED tail 
lamp, and accessory DC power points.

• Capacitor: The capacitor suppresses voltage 

spikes and ensures consistent voltage throughout 
the DC-CFI (RED-RED/WHT) circuits.

• Chassis Relay: The chassis relay on DC-CFI 

models supplies power to the MFD gauge, 
accessory plug and DC power test plug. 

• Ignition Coils: Provide ignition energy to each 

spark plug. Both coils are fired at the same time.

• Fuel Injectors (4 Injector): This system features 

a set of fuel injectors mounted to the crankcase, 
and a set of fuel injectors mounted to the cylinders 
(ports).

• Fuel Injectors (2 Injector): This system features 

a set of fuel injectors mounted to the cylinders 
(ports).

• Detonation Sensor: Located on the cylinder 

head, the detonation sensor transforms internal 
acoustic information into a signal the ECU uses to 
determine the amount of engine knock.

• Exhaust Valve Solenoid: Activated by the ECU, 

the solenoid controls the VES venting. When 
powered, the solenoid is open allowing cylinder 
pressure to vent, and the exhaust valves remain 
closed (down). When power is removed, the 
solenoid closes and the exhaust valves will lift.

• Throttle Position Sensor (TPS): The TPS relays 

the position of the throttle plates (operator throttle 
input) to the ECU.

• Coolant Temperature Sensor: Relays the engine 

temperature to the ECU.

• Exhaust Temperature Sensor: Relays the 

temperature of the exhaust pipe to the ECU.

• Temperature / Manifold Air Pressure

(T-MAP) Sensor: Relays the current intake air 
temperature and ambient air pressure to the ECU. 
The sensor is located on the airbox.

• Vehicle Speed Input: The ECU monitors the 

vehicle speed supplied by the vehicle speed 
sensor.

• Fuel Pump: Supplies fuel to the fuel injectors. 

Power to the fuel pump is supplied by the 
regulator / rectifier.

• Diagnostic Connector: The ECU can 

communicate with the Polaris Digital Wrench 
software and can be re-flashed, monitored and will 
display trouble codes.

• AC Regulator/Battery Charge Rectifier: The 

head lamps and hand/thumb warmers are 
powered by AC voltage. If snowmobile is 
equipped with electric start, the regulator/rectifier 
supplies DCV to charge the battery.

CAUTION

CFI and DC-CFI ECUs cannot be interchanged. Serious 

engine damage may occur.

4.7

Cleanfire Fuel Injection

4

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

© 2011 Polaris Sales Inc.

DC-CFI-2/4 Fuel Select Modes

DC-CFI-2/4 models allow the operator to select between 
91+ octane non-oxygenated fuels or <91 octane or 
oxygenated fuels.

The fuel selector resistor plug is located on the main wiring 
harness attached to the over structure behind the left-side 
door panel

When using <91 octane, oxygenated, or when unsure of 
the fuel type inside the fuel tank, plug the 10% ETHANOL/
24 OHM resistor into the fuel selector plug. 

When using 91+ non-oxygenated fuels, install the NON-
ETHANOL/160 OHM resistor into the fuel selector plug.

<91/10% ETHANOL/24 OHM Resistor Plug

Part Number =2411280 (Installed at the factory.)

91+ NON-ETHANOL/160 OHM Resistor Plug

Part Number =2411282 (Included in tool kit.)

Dual Resistor Fuel Selector Plug

2012 models are equipped with one fuel selector plug 
featuring dual resistors. The part number for the plug is 
2411631 and it can be used on all DC-CFI models.

CAUTION

Always verify the ETHANOL resistor plug is installed in 

the selector plug if unsure of fuel type. Severe engine 

damage may occur if the PREMIUM resistor plug is 

installed when using ethanol-blended fuel.

Never use fuels containing more than a 10% ethanol 

blend.

Lock Screw

FUEL RESISTOR PLUG

OIL TANK

Lock Screw

Lock Screw

 

 

 

 

 

 

 

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