Snowmobile Polaris 600 RUSH (2010 year). Instruction - part 29

 

  Index      Snowmobiles / ATV     Snowmobile Polaris 600 RUSH - instruction 2010 year

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  27  28  29  30   ..

 

 

Snowmobile Polaris 600 RUSH (2010 year). Instruction - part 29

 

 

4.12

Cleanfire Fuel Injection

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

© 2011 Polaris Sales Inc.

ECU 26 Pin Connector (Engine)

NOTE:  Wire Entry View

PIN

 

COLOR

GOES

 

TO

 

CONNECTOR

FUNCTION

1

DARK BLUE

FUEL INJECTOR HARNESS PLUG

PTO CRANKCASE INJECTOR DRIVER

(DC-CFI-4)

2

DARK BLUE/WHT

PTO CYLINDER INJECTOR DRIVER

3

RED/DARK BLUE

FUEL INJECTOR POWER SUPPLY (16 VDC)

4

DARK GREEN

5 TOOTH CPS SENSOR

SENSOR SIGNAL

5

WHT/GRN (2011=BRN/WHT)

STATOR CPS HARNESS CONNECTOR

SENSOR GROUND

6

BLK/BLU

TPS CONNECTOR

EXHAUST TEMP. SENSOR

COOLANT TEMP. SENSOR

TMAP SENSOR CONNECTOR

COMMUNICATION CONNECTOR

SENSOR GROUND

7

AQUA

TPS CONNECTOR

TPS SIGNAL RETURN

8

YEL/RED

COOLANT TEMP. SENSOR

COOLANT TEMP. SIGNAL

9

BLK/WHT

DETONATION SENSOR

SIGNAL GROUND

10

YEL/WHT

COMMUNICATION CONNECTOR

TxD SIGNAL (TRANSMIT)

11

WHT/BLK

RxD SIGNAL (RECEIVE)

14

YELLOW

FUEL INJECTOR HARNESS PLUG

MAG CRANKCASE INJECTOR DRIVER

(DC-CFI-4)

15

YEL/WHT

MAG CYLINDER INJECTOR DRIVER

16

RED/BLU

FUEL INJECTOR POWER (16 VDC)

17

WHITE

2 TOOTH CPS SENSOR

SENSOR SIGNAL

18

RED

IGNITION COIL CONNECTOR

COIL POWER

19

BLACK

COIL GROUND

20

GRAY

TMAP SENSOR CONNECTOR

INTAKE PRESSURE SIGNAL

21

ORANGE

STATOR SYSTEM POWER CONNECTOR

FUEL INJECTOR BOOST POWER

22

WHT/BLK

EXHAUST TEMP. SENSOR

EXHAUST TEMP. SIGNAL

23

PINK

TMAP SENSOR CONNECTOR

INTAKE AIR TEMP. SIGNAL

24

RED/WHT

TPS CONNECTOR

TMAP SENSOR CONENCTOR

COMMUNICATION CONECTOR

5VDC SENSOR VOLTAGE

25

PURPLE

DETONATION SENSOR

SENSOR SIGNAL

26

ORANGE

STATOR SYSTEM POWER CONNECTOR

FUEL INJECTOR POWER

4.13

Cleanfire Fuel Injection

4

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

© 2011 Polaris Sales Inc.

Exhaust Temperature Sensor

Temperature / Air Pressure Sensor (TMAP)

Crankshaft Position Sensors (CPS)

The 5 tooth crank position sensor picks up all 5 flywheel 
teeth and determines the following:

• Judge direction of rotation (forward and backward)

• Ignition advance angle control

• Injector drive angle control 

• Excess advance ignition control at reverse

• MAG / PTO cylinder detection

The 2 tooth crank position sensor picks up 2 flywheel 
teeth. It detects the crank angle and obtains minimal 
information of the crank angle when control enters into 
limp home mode

The sensors must be in the correct position or the engine 
will not run. A sheared flywheel key will cause the engine 
to not start or to shut off (misfire).

Crankshaft Position Sensor Air Gaps

Hard engine starting, erratic reverse operation, and poor 
engine performance can occur if the CPS air gap(s) are 
outside specification.

NOTE:  The sensor bases are not slotted. Only minor 
deflection adjustments can be made.

Air Gap Inspection/Adjustment

1.

Rotate the crankshaft/flywheel so that an encoder rib 
is positioned directly underneath the sensor being 
measured.

Sensor Specifications

Resistance 

Values

2.3M

 @ 392_F (200_C)

76

 @ 1652_F (900_C)

T 

Exhaust Temperature Sensor Torque:

32 ft-lb (44 Nm)

Sensor Specifications

Pins 1 to 2 (Temperature)

59_F (15_C) = 3000

68_F (20_C) = 2500

77_F (25_C) = 2000

Pins 1 to 4 (Pressure)
Pins 3 to 4 (Pressure)

2400 - 8200

3400 - 8200

In. / mm. 

Crankshaft Position Sensor Air Gap:

.020"-.030" (0.5-0.8mm)

TWO-TOOTH CPS

FIVE-TOOTH CPS

AIR GAP

4.14

Cleanfire Fuel Injection

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

© 2011 Polaris Sales Inc.

2.

Insert the blade of a .030" feeler gauge between the 
rib and sensor face. If there is no drag felt on the feeler 
gauge, the CPS must be adjusted.

3.

To adjust a CPS, use a 8 inch pry bar to carefully 
deflect the sensor.

4.

Place the tip of the small pry bar between the back of 
the sensor and crankcase. insert a .012" feeler gauge 
between the sensor face and encoder rib.

IMPORTANT: Do not pry on the individual sensor 
wires.

5.

Gently pry the sensor towards the encoder rip until the 
gauge begins to bind between the components.

6.

Re-measure the air gap. The gap should be between 
.020-.030.

Exhaust Valve Solenoid

Ignition Coils

PRY BAR

FEELER GAUGE

Specifications

Coil Resistance

(WHT/YEL to RED)

15

 +/- 15% @ 68°F (20°C)

Specifications

DC-CFI 4

DC-CFI 2

Primary Coil 
Resistance

(Black to White)

0.20

 +/- 15% 

@ 68°F (20°C)

0.45

 +/- 15% 

@ 68°F (20°C)

Secondary Coil 
Resistance

(Without Plug Cap/
Black to High Tension 
Lead)

6.3k

 +/- 15% 

@ 68°F (20°C)

18k

 +/- 15% 

@ 68°F (20°C)

Plug Cap Resistance

5k

+/- 15% @ 68°F (20°C)

4.15

Cleanfire Fuel Injection

4

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

© 2011 Polaris Sales Inc.

Engine Coolant Temperature Sensor

Knock (DET) Sensor

Throttle Body Removal

1.

Remove the oil tank/clutch cover assembly.

2.

Remove the airbox assembly.

3.

Pinch off the coolant lines with the hose pincher tool 
PN PU-45149.

4.

Remove the coolant hoses from the throttle body. 
Disconnect the TPS harness connector.

5.

Loosen the intake boot clamps and pull the throttle 
body upward. Locate the oil pump linkage arm. Pop 
the rod end off the throttle body cam.

6.

Loosen the throttle cable lock nut and remove the 
cable from the throttle body.

7.

Remove throttle body.

8.

During installation, verify the oil pump lever is not 
rotated over-center before installing the linkage arm 
on to the throttle body.

Sensor Specifications

Operating Temperature 
Range

-22_F - +248 _F

(-30_C - 120_C)

Resistance

2.4 - 2.6K

@ 68_F (20_C)

(Measure in stirred water)

Installation Torque

29 ft-lb (39.2Nm)

T 

Knock Sensor Screw Torque:

168 in-lb (19 Nm) Install screw clean and dry.

 

 

 

 

 

 

 

Content   ..  27  28  29  30   ..