Snowmobile Polaris 600 RUSH (2010 year). Instruction - part 30

 

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Snowmobile Polaris 600 RUSH (2010 year). Instruction - part 30

 

 

4.16

Cleanfire Fuel Injection

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

© 2011 Polaris Sales Inc.

DC-CFI-4 FUEL INJECTORS/FUEL 
RAIL

Fuel Injectors

Fuel Rail Bleeding / Pressure Testing

All CFI engine fuel return hoses feature an inline Schrader 
valve that can be used to bleed the fuel system pressure 
and observe fuel system pressure when using the fuel 
pressure gauge and specified adapter.

Fuel Pressure Gauge (PU-43506-A)

Fuel Pressure Gauge Adapters

• A = 314249 (.305-32 shallow core fitting/adapter 

supplied with PU-43506-A Fuel Pressure Gauge)

• B = PS-48617 (.305-32 deep core fitting)

• C = PS-48762 (7/16-20 fitting)

1.

Select the appropriate adapter.

2.

Connect the adaptor to the fuel return hose Schrader 
valve.

3.

Connect the adapter to the fuel pressure/bleed tool 
gauge.

4.

To observe running fuel system pressure, start the 
engine and compare reading to the specification.

NOTE: Observe pressure reading at idle and while 
operating the vehicle.

Specifications

Resistance

12

@ 68_F (20_C)

Fuel Pressure Gauge/Adapters

YEAR

 / 

MODEL

ADAPTERS

 

GAUGE

/

BLEED

 

TOOL

600 DC-CFI-4

PRO-RIDE

Shallow Core

314249

(.305-32 Shallow Core fitting 
supplied with PU-43506-A)

PU-43506-A

OEM PART NUMBER

SCHRADER VALVE

T0 FUEL RAIL

TO FUEL TANK

In. / mm. 

Fuel System Pressure:

58-60 (4.0-4.1)

PU-43506-A

CONNECT TO ADAPTER

A

B

C

4.17

Cleanfire Fuel Injection

4

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

© 2011 Polaris Sales Inc.

5.

To bleed the fuel system pressure after the engine is 
stopped, place the tool’s bleed hose into an 
appropriate fuel handling container. Open the valve to 
release the pressure and drain residual fuel.

6.

Close the valve, then remove the gauge and adapter 
from the fuel hose Schrader valve. Replace the 
Schrader valve dust cap.

Disconnect Fittings

The fuel hoses feature disconnect fittings that require 
special tools to remove. 

The fuel line disconnect tool kit, PS-47152, supplies one 
5/16

 and one 3/8

 quick disconnect tool. These tools are 

also commercially available at local auto parts stores.

1.

To disconnect a fuel hose from the fuel pump, or fuel 
rail, insert the tapered end of either the 5/16

 or 3/8

tool into the female housing.

2.

Push the tool into the housing to release the spring 
clamps. Carefully separate the hose from the 
connection.

3.

Reconnect the fuel hoses by coating each hose end 
with a light film of two stroke engine oil.

4.

Carefully install the male end of the hose into the 
center of the female housing. Firmly push the hoses 
together until the male nozzle fully seats behind the 
spring tabs and an audible “click” is heard.

5.

Grasp both hoses and gently pull to verify positive 
engagement.

Fuel Rail/Injector Removal/Installation

NOTE: 

Leave protective caps installed until 

instructed to remove. Avoid touching the tip of the 
injector.

A fuel injector, regardless of color code, can be accurately 
identified by the OEM part number stamped on plastic 
injector housing.

• 600 = OEM PN 1203491

When replacing a faulty fuel injector, always verify the part 
number of the injector for the engine application and use 
the same color code. If replacing an injector with a different 
color code, all of the fuel injectors must be replaced with 
the new color so all four injectors are the same color.

After replacing the injectors, the ECU must be re-flashed 
so the fuel calibration map matches the new color coded 
fuel injectors.

1.

Depressurize the fuel rail. See “Fuel Rail Bleeding / 
Pressure Testing” on page 4.16.

PS-47152

3/8

 DISCONNECT TOOL

600 INJECTOR KITS

INJECTOR 

KITS

COLOR

2203894-053

Yellow

2203894-027

Blue

2203894-015

Red

CAUTION

ALWAYS CHECK THE INJECTOR PART NUMBER TO 

VERIFY ENGINE APPLICATION REGARDLESS OF COLOR 

CODE.

NEVER RUN THE ENGINE WITH DIFFERENT COLOR-

CODED FUEL INJECTORS. SEVERE ENGINE DAMAGE 

WILL OCCUR.

ALWAYS VERIFY THE ECU CALIBRATION FILE MATCHES 

THE FUEL INJECTOR COLOR CODE.

OEM PART NUMBER

BLUE OR BLACK O-RING

BROWN OR GREEN O-RING

GREEN BUSHING

4.18

Cleanfire Fuel Injection

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

© 2011 Polaris Sales Inc.

2.

Remove the panduit straps as shown.

NOTE: The engine must be removed from the 
engine compartment to access the lower two fuel 
injectors.

3.

Remove the hex screws securing the fuel rail to the 
cylinders.

4.

If replacing a lower injector, remove the two bottom 
screws bolts from the lower fuel rail.

5.

Remove the failed injector(s).

NOTE:  Make sure that the green bushing comes out 
with the injector. If it does not, look inside the 
injector bore.

6.

Measure from the end of the injector (as shown 
below) 

3" (76.2mm) and cut the injector off.

7.

Strip the harness end injector wire covering .25" - 
.375" (6.35 - 9.525mm).

8.

Crimp the ends of the new injector firmly on to the wire 
harness.

GREEN BUSHING

BROWN OR GREEN O-RING

BLUE OR BLACK O-RING

3” (76.2mm)

4.19

Cleanfire Fuel Injection

4

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

© 2011 Polaris Sales Inc.

9.

Tape exposed wire and splices.

10. Apply oil to the fuel injector o-rings.

11. Remove the protective caps. Install the injector(s) into 

the fuel rail. Verify the injector(s) are fully seated.

12. Insert the fuel rail, with injectors into the engine.

13. Apply a light amount of 262 Loctite® to the fuel rail 

fasteners and torque to specification.

14. Replace the harness to the original routing and apply 

panduit straps back to the original locations.

NOTE:  Refer to Step 2 for proper routing and strap 
location.

15. Install the engine if it was removed. 

16. If different color injectors were installed, re-flash the 

ECU to the new color code.

T 

Fuel Rail Hex Screw Torque: 9 ft-lb (12Nm)

 

 

 

 

 

 

 

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