Original Comprehensive 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
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Sample pages from the Original Comprehensive 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 manual
Purchase Information
Technical Specifications
- Document Number / Seller:
- 32215 / Steven Morgan
- File Size:
- 50.13 MB
- File Type:
- Language:
- English
- Pages:
- 512
- Printable:
- Yes
- Estimated Download Time:
- 1.03 Minutes
- Delivery Format:
- Digital (PDF) - Instant Access
- Category:
- Snowmobile
- Brand:
- Polaris
- Reviewed and Approved:
- Jan 1, 2026
Polaris Models and Parts Covered in this Snowmobile Manual
- Polaris 600 RUSH (2010-2013)
- Polaris 600 RUSH LX (2011)
- Polaris 600 RUSH PRO-R (2011-2013)
- Polaris 800 RUSH (2011-2013)
- Polaris 800 RUSH LX (2011)
- Polaris 800 RUSH PRO-R (2011-2013)
- Polaris 800 RUSH PRO-R LE (2012-2013)
- Polaris 800 SWITCHBACK ASSAULT (2011-2013)
- Polaris 800 RMK 155 (2011-2013)
- Polaris 800 RMK ASSAULT (2011-2013)
- Polaris 800 PRO RMK 155 (2011-2013)
- Polaris 800 PRO RMK 163 (2011-2013)
- Polaris 600 SWITCHBACK (2012-2013)
- Polaris 800 SWITCHBACK (2012-2013)
- Polaris 600 SWITCHBACK PRO-R (2012-2013)
- Polaris 800 SWITCHBACK PRO-R (2012-2013)
- Polaris 600 SWITCHBACK ADVENTURE (2012-2013)
- Polaris 600 RMK 144 (2012-2013)
- Polaris 600 RMK 155 (2012-2013)
- Polaris 600 PRO RMK 155 (2012-2013)
- Polaris 600 INDY (2013)
- Polaris 600 INDY SP (2013)
- Polaris 800 SWITCHBACK PRO-R ADVENTURE (2013)
Complete Manual Information
Polaris RUSH, RMK, Switchback, and Indy Factory Service Manual - 2010-2013
Operational integrity of the Polaris Pro-Ride chassis snowmobile fleet depends on adherence to factory-specified tolerances and high-modulus bonding protocols. This authoritative workshop manual delivers the technical architecture required for engine overhauls, Cleanfire fuel injection calibration, and progressive suspension synchronization. A critical maintenance requirement for structural uptime involves the engine mount fasteners; technicians must differentiate between the 14mm green/silver bolts used on 2010-2011 models and the 16mm knurled replacements required for 2012-later units to prevent bulkhead stress fractures and maintain proper drive clutch alignment.
Technical Applicability & Engine Configurations
The following model ranges are categorized by engine displacement and chassis architecture as defined in the factory specifications:
600cc Liberty Liquid-Cooled / Case Reed Induction
- RUSH Series (2010-2013): 600 RUSH, 600 RUSH LX, 600 RUSH PRO-R.
- RMK Series (2012-2013): 600 RMK 144, 600 RMK 155, 600 PRO RMK 155.
- Switchback Series (2012-2013): 600 Switchback, 600 Switchback Adventure, 600 Switchback PRO-R.
- Indy Series (2013): 600 INDY, 600 INDY SP.
800cc Liberty Liquid-Cooled / Case Reed Induction
- RUSH Series (2011-2013): 800 RUSH, 800 RUSH LX, 800 RUSH PRO-R, 800 RUSH PRO-R LE.
- Switchback Series (2011-2013): 800 Switchback, 800 Switchback Assault (1.3/2.0), 800 Switchback PRO-R Adventure.
- RMK Series (2011-2013): 800 RMK 155, 800 RMK Assault, 800 PRO RMK 155/163.
ROI Benchmarks & Reliability Standards
- Digital Wrench® diagnostic protocols provide precise ECU reflashing and fuel map calibration, protecting high-performance Liberty engines from detonation-induced failure.
- Factory-validated suspension tuning matrices for Pro-Ride Progressive and RMK Coil-Over systems ensure optimal weight transfer and rider safety across variable terrain.
- Explicit bonding instructions for Lord 406 Acrylic Adhesive on chassis supports preserve the structural rigidity required for high-velocity operation.
Technical Metadata
- Document Type: Factory Service & Repair Manual
- Production Cycle: 2010 - 2013
- System Focus: DC-CFI Fuel Systems, PVT Drive Units, Pro-Ride Chassis
- Chapter Count: 10 Technical Sections
Calibration Parameters & Factory Benchmarks
- Cylinder Architecture: Piston-to-cylinder clearance for 600cc engines is established at 0.0033–0.0054 inches (0.085–0.137mm), with a definitive service limit of 0.009 inches.
- PVT Drive Calibration: Drive clutch bolt torque is fixed at 80 ft-lbs (108 Nm) for all DC-CFI models and requires re-torquing after the initial engine heat cycle.
- Crankshaft Integrity: Maximum crankshaft runout deflection is limited to 0.0025 inches (0.07mm) to mitigate bearing vibration and premature seal wear.
- Electrical Output: Stator lighting charge coils deliver 400 Watts at 13.5 VDC, regulated between 13.5–14.5 VDC for chassis power.
Visual Navigation & Diagnostic Aids
- Component Torque Sequences: Includes standardized patterns for cylinder heads, CFI crankcases, water pump covers, and monoblock cylinder configurations.
- Altitude Gearing Matrices: Comprehensive tables provide shift weight, spring rate, and helix specifications for elevations ranging from sea level to 12,000 feet.
- Structural Bonding Layouts: Detailed illustrations indicate adhesive lines for Lord 406 application on support braces and bonded chaincases.
- CFI Troubleshooting Flowcharts: Step-by-step logic paths for resolving detonation (dET) limits and exhaust gas temperature (EGT) sensor faults.
Table of Contents
- Chapter 1: General Information (Model Specifications, VIN Decals, Publication Part Numbers)
- Chapter 2: Maintenance (Break-in Procedures, Periodic Maintenance Table, Fluid Capacities)
- Chapter 3: Engine/Cooling/Exhaust (Fastener Torque Guide, Engine Mounting, Overhaul Specs)
- Chapter 4: Cleanfire Fuel Injection (Fuel Selection Mode, TPS Calibration, Digital Wrench)
- Chapter 5: Final Drive/Brake System (Gearing Charts, Bonded Chaincase, QuickDrive System)
- Chapter 6: PVT System (Drive/Driven Clutch Theory, Spring Rates, Clutching Matrices)
- Chapter 7: Shocks (Gas Recharging, Valve Shim Arrangement, Walker Evans/Fox Service)
- Chapter 8: Steering and Suspensions (Front/Rear Suspension Settings, Camber/Toe Specs)
- Chapter 9: Chassis (Hood/Bodywork, Seat Support, Adhesive Bonding Protocols)
- Chapter 10: Battery and Electrical Systems (Schematics, Instrument Cluster, Ignition Timing)
Operational Limits & Lubricant Specifications
- Fuel Grades: 91+ Octane (Non-Oxygenated) for Premium mode; 87-91 Octane (max 10% Ethanol) for Ethanol mode.
- Chaincase Lubrication: Requires Polaris Synthetic 80W Gear Lube with a capacity of 9 oz (266 ml).
- Cooling System: Polaris Premium 60/40 pre-mixed antifreeze rated to -62°F (-52°C).
- Brake Hydraulics: Use exclusively ethylene-glycol based DOT 4 high-temperature fluid.
- Variable Exhaust System: Polaris VES Gold Plus Synthetic engine oil is required to maintain exhaust valve guillotine cleanliness.
Download Instructions for Polaris Snowmobile Manual
Frequently Asked Questions - Polaris Snowmobile Manual
Is this manual suitable for beginners?
Yes, this Polaris manual is designed for both professional technicians and DIY enthusiasts. It includes step-by-step procedures with clear illustrations and safety guidelines for Snowmobile maintenance and repair.
What file format will I receive?
You will receive this manual as a PDF file (50.13 MB), which is compatible with all devices. The manual is fully searchable and printable for your convenience.
How quickly can I access the manual after purchase?
You'll receive instant access to your Polaris Snowmobile manual immediately after payment completion. The download link is valid for 3 days, with lifetime re-download guarantee.
Can I print specific sections of the manual?
Absolutely! This digital manual allows you to print any section you need, from individual pages to complete chapters, making it perfect for workshop use.
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