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

Comprehensive service, repair, and maintenance manual covering Polaris 600 and 800 RUSH, RMK, and Switchback snowmobiles from 2010-2013. Includes detailed procedures and diagrams for all major systems.

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Document Details

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Document Number / Seller:
32215 / Steven Morgan
File Size:
50.13 MB
File Type:
PDF
Language:
English
Pages:
512
Printable:
Yes
Category:
Snowmobile
Last updated / verified
Jan 1, 2026

Models Covered & Key Technical Specifications

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

Polaris Snowmobile Service Manual | Models 600, 800 Rush, Switchback, RMK, Assault | 2010-2013.

  • Engine Specifications: 599cc / 2 cylinders for 600 models; 794cc / 2 cylinders for 800 models.
  • Bore: 3.04 inches (77.25 mm) for 600 models; 3.34 inches (85 mm) for 800 models.
  • Stroke: 2.52 inches (64 mm) for 600 models; 2.75 inches (70 mm) for 800 models.
  • Cooling System Capacity: 5.25 / 5.0 Qts/L for 600 models; 6 / 5.7 Qts/L for 800 models.
  • Drive Belt Part Number: 3211122.
  • Spark Plug Gap: .027" (.70mm).

Professional Workshop Service Manual & Technical Specifications

OEM-Grade Factory Overhaul Manual: Polaris 600 RUSH, 800 RUSH, 800 Switchback Assault, 800 RMK 155, 800 PRO RMK 155/163, 600 PRO RMK 155, 600 INDY Snowmobile (2010-2013) - Factory Service & Repair Manual Technical-Briefing

Serial-Range: 2010-2013 // Engineering-Metrics: 599cc, 794cc, 46mm Throttle Bore, 48mm Throttle Bore // Machine-Range: Snowmobile

Metric Value Context
Engine Displacement 599cc - 794cc Varies by model specification.
Bore x Stroke (600cc) 3.04 x 2.52 inches Standard measurement for engine components.
Bore x Stroke (800cc) 3.34 x 2.75 inches Engine cylinder and piston dimension.
Piston to Cylinder Clearance .0033-.0054 inches (0.085-0.137 mm) Critical tolerance for engine operation.
Idle RPM 1700 Engine speed at idle operation.
Ignition Timing 18° @ 1700 RPM Timing advance for ignition system.
IFS Spring Rate 80-170 lbs/in Varies by model and suspension type.
Rear Travel 14-16.5 inches Suspension travel specification.

Technical content addresses maintenance, diagnostics, and repair procedures for a wide range of Polaris 600 and 800cc snowmobiles from 2010 to 2013. This manual covers specific models including RUSH, Switchback, RMK, and INDY variants, detailing procedures for engine, fuel system, electrical, and chassis components. It also includes comprehensive specifications for suspension, clutches, and engine mounting.

FAQ

What **documented** safety precautions should be followed when working with the fuel system? keyboard_arrow_down

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.

Confirm the **precise** lubrication requirements for the drive belt and clutches. keyboard_arrow_down

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.

What **proper** testing parameters are required for the fuel rail and injectors? keyboard_arrow_down

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.

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This manual is a must-have for anyone with a 2010-2013 Polaris snowmobile. The diagrams are clear and the instructions are easy to follow. Plus, the download process was seamless and the support team was incredibly responsive!