2010-2013 Polaris 600 800 Rush Switchback RMK Snowmobile Service Manual

Always ensure the work area is well-ventilated and free from ignition sources like open flames, sparks, or heaters when servicing the fuel system. Never drain the fuel system when the engine is hot, as severe burns may occur from escaping fuel or steam. Always wear eye protection and wash any spilled gasoline from skin or clothing immediately with soap and water.

The drive belt should be stored in its original packaging and not hung from a hook to prevent damage. For clutch lubrication, use a light oil or rust inhibitor on sheave faces and ramps; ensure all lubrication is cleaned off before installing the belt. Always use new lock nuts when replacing ski skag fasteners and when servicing ski-to-spindle fasteners.

To test fuel system pressure, connect a Mity Vac hand pump to the fuel tank vent fitting or use the Fuel Line Adapter. Pressurize the tank to 5 PSI (34 Kpa) and check for leaks around the PFA gasket. If bubbles form, re-check PFA nut torque or replace the gasket. Always verify the ECU calibration file matches the fuel injector color code, as using incorrect injectors can cause severe engine damage.