Polaris 600/800 Rush, Switchback, RMK & Indy Service Manual 2010–2013 (P/N 9923839)

Polaris 2010–2013 PRO-RIDE service manual P/N 9923839 covers the listed Rush, Switchback, RMK and 600 Indy/Indy SP snowmobiles, including specified Assault, Pro-R, Adventure and international variants. Coverage is model-specific: the 2010 entry is the 600 Rush, while the Indy entries apply to 2013.

Searchable Text, Bookmarks and Wiring Detail

Text access and diagram detail: The service text supports PDF text search, with extensive embedded bookmarks for chapters and individual topics. Detail labels in the 2010–2012 wiring sheets are not text-searchable. Small wire codes and connector labels on the wiring sheets require zooming.

One printable, English-language PDF contains 512 pages, including 28 wiring-diagram pages and three notes pages.

Liberty Engine, Cleanfire and Chassis Service

The following selected service topics outline the repair coverage. Other subjects include off-season storage and instrument-cluster security functions.

• Engine and cooling: Step-by-step engine removal, cylinder and piston service, crankcase disassembly, water/oil-pump service, thermostat replacement and cooling-system bleeding.

• Cleanfire fuel injection: DC-CFI-4 and DC-CFI-2 injector service, fuel-pressure testing, TPS checks, Digital Wrench procedures and Diagnostic Trouble Code troubleshooting.

• PVT and final drive: Drive-clutch rebuilding, TEAM LWT and SPA-P2 driven-clutch service, clutch alignment, chaincase repair and QuickDrive belt/sprocket replacement.

• Hydraulic brakes: Fluid replacement and bleeding, master-cylinder service, brake-disc replacement, and Phantom/Phantom Lite caliper piston, seal and pad procedures.

• Shocks and suspension: FOX and Walker Evans shock rebuilding, valve-stack specifications, steering alignment, rear-suspension removal and spring setup.

• Electrical diagnosis: Ignition and charging-system tests, electric-start schematics, ECU connector pinouts and model-specific chassis, engine and hood wiring diagrams.

Suited to technicians and mechanically experienced owners with appropriate measuring equipment; the clutch chapter specifically recommends Polaris-trained authorized technicians for clutch adjustments and repairs.

Engine Build Details and Maintenance Planning

The 64-page model-specification section pairs vehicle data with more than 25 clutch-setting tables, including altitude-based configurations. Standard and metric bolt-torque charts provide a separate general reference.

Cylinder-measurement worksheets, piston and bearing inspection limits, crankshaft runout checks and truing guidance support internal engine repair. Separate identification details distinguish Type 1 and Type 2 DC-CFI-2 crankshafts for service-parts selection. Nicasil-cylinder guidance covers light honing rather than oversize boring.

The maintenance section maps out periodic service tasks for brakes, steering, suspension and the air intake. Oil-pump adjustment, bleeding and hose priming receive dedicated procedures; trapped air in the oil supply can cause severe engine damage.

Cleanfire Diagnosis and Digital Wrench

The fuel sections distinguish the four-injector system used on earlier 600 configurations from the two-injector systems used on later 600 and covered 800 models. Injector part-number and color-code information is linked to ECU calibration selection.

Digital Wrench coverage includes live data, guided diagnostics, ECU replacement and reprogramming. TPS procedures distinguish idle adjustment, base-setting work and throttle-body synchronization, with restrictions on disturbing factory settings.

The DC-CFI Troubleshooting Flowchart and Detonation Limit Troubleshooting Flowchart organize symptom checks across fuel, ignition, exhaust and sensor systems. Separate ECU chassis and engine connector tables support circuit identification.

Clutches, Brakes and QuickDrive

The PVT chapter explains clutch operation before detailing wear diagnosis, bushing and roller work, belt-to-sheave clearance and spider indexing. SPA-P2 cover and sheave bushings are identified as non-serviceable; excessive wear calls for clutch-assembly replacement.

Final-drive coverage distinguishes bonded and non-bonded chaincases from the QuickDrive Low Inertia Drive System. Assembly views and the Gear Ratio Speed Chart accompany shaft, bearing and gearing information.

Brake coverage separates Phantom and Phantom Lite calipers, with the related mounting, seal and piston differences.

Shock Rebuilding, Suspension and Bonded Chassis

FOX IFP, PS-5 and Zero Pro procedures sit alongside Walker Evans monotube and remote-reservoir rebuilding instructions. Valve Shim Arrangement charts, piston-orientation views and model-specific IFP-depth tables support assembly.

The Walker Evans remote-reservoir procedure warns that rapid rod insertion can displace the IFP and affect damping performance. Listed tools include the IFP Depth Tool 2871351 and Gas Fill Tool PS-45259.

Suspension sections distinguish Progressive and RMK coil-over layouts. Bonded-chassis procedures cover surface preparation and Lord 406 adhesive application; bonded overstructure/support assemblies are treated as complete replacement units.

Ignition, Power Circuits and Wiring

Electrical coverage separates regulated DC, chassis DC and AC lighting circuits. Component tests address the stator, regulator/rectifier, ignition coils, switches and hand/thumb warmers, with an electric-start system schematic and harness drawings for fault tracing.

Together, the model tables, component tests and circuit documents help match a repair task to the installed configuration before parts or test procedures are selected.

A Preview of TPS and Clutch Specifications

The TPS test section specifies idle-voltage ranges of 0.94–0.96 VDC for 600 DC-CFI engines and 0.93–0.95 VDC for 800 DC-CFI engines. These are Digital Wrench readings with correct throttle-cable free play and a sensor-reference voltage of 4.9–5.0 VDC.

The model tables specify 80 ft-lb (108 Nm) for the drive-clutch retaining bolt and call for re-torquing after engine operation.

Engine handling and pressurized shock service require suitable lifting and charging equipment. Follow the manual’s precautions and use qualified service support for major overhauls.