Target Audience:
Owners of Polaris 600 RUSH snowmobiles seeking to perform their own maintenance and repairs, independent repair shops.
Value Proposition:
Provides substantial cost savings compared to dealership service, empowers users with knowledge to maintain and repair their vehicle effectively.
Completeness:
Comprehensive coverage of all major systems, offering a complete guide for upkeep and repair.
Usability:
Step-by-step instructions and diagrams are designed for clarity and ease of use by individuals with varying levels of mechanical experience.
Engine:
Detailed diagnosis, disassembly, reassembly, overhaul, lubrication, cooling system, fuel system (carburetion, fuel pump, filters), exhaust system, starter system, recoil starter.
Drivetrain:
Clutch (removal, installation, adjustment), transmission servicing, gearbox removal, axle shaft removal, CV joint replacement.
Cooling Heating:
Radiator, fan, oil cooler, coolant hoses, fan shroud, AC condenser (if applicable), heater system components.
Electrical:
Comprehensive wiring diagrams, sensor testing and diagnosis, ignition system components, electrical component testing, troubleshooting common electrical faults.
Suspension:
Front and rear suspension components, shock absorber servicing and adjustment, strut replacement, suspension geometry checks (if applicable).
Brakes:
Brake system diagnosis, disc replacement, pad installation, hydraulic system components.
Bodywork Exterior:
Body panel removal and installation (hood, fenders, doors), trim components, bumpers, emblems, fuel cap and door, grilles, glass (windshield, windows).
Interior:
Interior panel removal, console components, seat removal, floor mats, cargo liners.
Wheels Tires:
Tire replacement, rotation, lug nut torque specifications, hub cap and wheel cover removal/installation.
Maintenance:
Scheduled maintenance, oil changes, filter replacements, spark plug checks, lubrication points, track tension adjustment.
Troubleshooting:
Systematic diagnostic procedures for common and uncommon problems across all major vehicle systems.
Repair:
Detailed step-by-step repair instructions for component disassembly, reassembly, and adjustment.
Installation:
Guidance for installing new or replacement parts, including clutches, suspension components, and body panels.
Depth:
Comprehensive, covering from basic maintenance to major overhauls and component-level repairs. Suitable for both DIY enthusiasts and professional technicians.
Format:
PDF (Portable Document Format)
Quality:
Designed for clear viewing and printing, featuring high-resolution diagrams and text.
Binding:
N/A (Digital PDF download)
Paper Type:
N/A (Digital PDF download)
Searchability:
Likely text-searchable, allowing users to quickly find specific topics and keywords.
Illustrations:
Includes hundreds of detailed diagrams and illustrations to aid in comprehension of repair procedures.
Engine Type:
2-Stroke, Parallel-Twin Cylinder
Displacement:
599cc (approximate)
Cooling System:
Liquid-Cooled
Horsepower Range:
Typically in the 110-125 HP range for this era of Polaris 600 engine (specific output may vary slightly by model year).
Fuel Delivery:
Carbureted (likely Mikuni VM series or similar, specific size would be detailed in the manual)
Ignition System:
CDI (Capacitor Discharge Ignition), Electronic Fuel Injection (EFI) was becoming more common, but this era often featured advanced carburetion.
Oil System:
Premix or Autolube (Oil Injection System)
Type:
CVT (Continuously Variable Transmission) featuring Polaris P-85/P-90 primary clutch and roller cam secondary clutch.
Gear Selection:
Forward, Neutral, Reverse (often electrically actuated or manual lever operation)
Clutch Details:
Primary and Secondary clutch service, alignment, engagement/disengagement speeds, belt inspection and replacement.
Display Panel:
Features a digital instrument cluster displaying speed, RPM, fuel level, coolant temperature, and diagnostic information.
Efi System:
While primarily carbureted, some higher-spec models from this era might have featured early EFI systems for improved fuel management and performance. The manual would detail specific fuel system technology.
Diagnostic Ports:
Likely includes a diagnostic port for accessing engine control unit (ECU) data if applicable, aiding in troubleshooting.
Oil Change:
Refer to manual for specific interval (typically based on mileage or operating hours, e.g., every 100-200 hours or annually).
Clutch Service:
Regular inspection of clutch components, belt condition, and alignment recommended at specified intervals (e.g., annually or every 50-100 hours).
Track Tension:
Periodic adjustment of track tension is crucial for optimal performance and longevity.
Engine Oil:
Specific 2-stroke synthetic oil with appropriate TC-W3 or JASO FD rating recommended by Polaris. Manual will specify exact type and brand.
Coolant:
Ethylene glycol based antifreeze with corrosion inhibitors, mixed with distilled water (50/50 ratio typically). Manual will specify type and capacity.
Brake Fluid:
DOT 4 brake fluid is common for Polaris vehicles of this era. Manual will confirm.
Clutch Wear:
As with many CVT systems, clutch belt wear and potential for overheating if overloaded or improperly maintained is a common concern.
Cooling System Maintenance:
Ensuring proper coolant levels and flow through the radiator and heat exchangers is critical to prevent overheating, especially under heavy loads or warm conditions.
Suspension Bushings:
Wear in suspension bushings and linkages can occur over time, affecting handling and requiring periodic inspection and replacement.
Heritage:
Polaris is a long-standing American manufacturer of powersports vehicles, with a significant history in snowmobile innovation and performance.
Rush Platform:
The RUSH platform, introduced by Polaris, was designed to optimize weight distribution and rider-forward positioning for improved handling and rider-involvement. It represented a significant advancement in snowmobile chassis design.
Manufacturing Location:
Polaris vehicles are typically manufactured in the United States.
