2016 Polaris 800 Rush PRO-S Owners Manual

2016 Polaris 800 Rush PRO-S Manual

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2016 Polaris 800 Rush PRO-S manual content summary:

  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 1
    600 RUSH 800 RUSH 600 SWITCHBACK 800 SWITCHBACK Snowmobile Owner's Manual for Maintenance and Safety
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 2
    recommended and may result in voided warranty coverage. Please read the warranty section of this manual carefully. WARNING Read, understand, and follow all of the instructions and safety precautions in this manual and on all product labels. Failure to follow the safety precautions could result in
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 3
    operation of your vehicle, be sure to follow the instructions and recommendations in this owner's manual. Your manual contains instructions for minor maintenance, but information about major repairs is outlined in the POLARIS Service Manual and should be performed only by a factory certified Master
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 4
    omissions or inaccuracies. Any reprinting or reuse of the depictions and/or procedures contained within, whether whole or in part, is expressly prohibited. The original instructions for this vehicle are in English. Other languages are provided as translations of the original
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 5
    should be recorded in the owner's manual. Safety ...9 This section describes safe section includes a Suspension Quick Set-Up Guide and explains how to make additional suspension regular maintenance. POLARIS Products...Specifications ...Troubleshooting ...Warranty ...Maintenance Log ...Index ...
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 6
    4
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 7
    when the snowmobile is sold. Some of the illustrations and photos used in this manual are general representations. Your model may differ. Follow the maintenance program outlined in this manual. Preventive maintenance ensures that critical components of the snowmobile are inspected by your dealer
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 8
    of our environment, including wildlife and vegetation. Snowmobile clubs and other organizations are working together to protect our environment. Please support their efforts and operate your snowmobile with consideration for the protection and preservation of our environment. Noise Level One of the
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 9
    INTRODUCTION Vehicle Identification Numbers Record your snowmobile's identification numbers and key number in the spaces provided. NOTE: The Vehicle Identification Number (VIN) is stamped into the side of the tunnel and printed on the tunnel VIN label. Certification Label Tunnel VIN Emissions
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 10
    INTRODUCTION Engine Serial Number The engine serial number is located on the identification label on the engine recoil cover. Key Identification The ignition keys are etched with an identification number. Remove the spare key and store it in a safe place. Your key can be duplicated only by mating a
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 11
    on your vehicle. Your safety is involved when these words and symbols are used. Become familiar with their meanings before reading the manual. The safety alert symbol indicates a potential personal injury hazard. DANGER A DANGER indicates a hazardous situation that, if not avoided, will result in
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 12
    SAFETY Operator Safety Follow the recommended maintenance program beginning on page 98 of this manual to ensure that all critical components on the snowmobile are thoroughly inspected by your dealer at specific mileage intervals. WARNING Driving a snowmobile requires your full
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 13
    warming up the track. A loose track or flying debris could cause serious injury or death. We recommend having your dealer perform all track service and alignment procedures. NO STEP Stay Clear of Engine Never attempt adjustments with the engine running. Stop the engine before opening a side panel
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 14
    SAFETY Operator Safety Riding Apparel Helmet Wearing a helmet can prevent a severe head injury. Whenever riding a POLARIS vehicle, always wear a helmet that meets or exceeds established safety standards. Approved helmets in the USA and Canada bear a U.S. Department of Transportation (DOT) label.
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 15
    bag, a flashlight, food and water, a signaling mirror, a means of building a fire and a two-way radio or cellular telephone. Always carry the owner's manual on your snowmobile. For added protection, purchase and carry the following items on your snowmobile as well Spare Drive Belt Extra Set of
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 16
    SAFETY Operator Safety Rider Capacity Some POLARIS snowmobiles are designed for a single rider only, while some are designed for up to two riders. A safety label on the vehicle indicates whether the vehicle is designed for a single rider or for two riders. Driving With a Passenger Passenger Seat
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 17
    driver to slow down or stop if you are uncomfortable. Do not continue to ride on the vehicle if you cannot comfortably follow all instructions in this manual. 4. Always use an approved helmet and protective gear when riding. 5. During turns and maneuvers, shift your body weight in the same manner in
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 18
    SAFETY Operator Safety Excessive Speed WARNING! High speed driving, especially at night, could result in serious injury or death. Always reduce speed when driving at night or in inclement weather. Always observe all state and local laws governing snowmobile operation and speed limits. Always be
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 19
    if you break through the ice. Never travel on frozen bodies of water unless you have first verified that the ice is sufficiently thick to support the weight and moving force of the snowmobile, you and your cargo, together with any other vehicles in your party. Always check with local authorities
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 20
    SAFETY Operator Safety Avalanches Snowmobilers should always be properly trained and equipped before traveling in mountainous terrain Take an avalanche class Travel with experienced people Travel on designated trails Make sure each person is equipped with a shovel, probe and avalanche beacon. You
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 21
    may interfere with the steering of your snowmobile, resulting in serious injury or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 22
    SAFETY Operator Safety Driving Downhill When riding downhill, shift your weight to the rear of the snowmobile and reduce your speed to a minimum. Apply just enough throttle to keep the clutch engaged, allowing the engine's compression to help slow the snowmobile and keep it from rolling freely
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 23
    removed. NOTICE: Damage to the engine may occur if the intake silencer or filter are removed. Clutches Do not attempt to service the clutches. All clutch service must be performed by your dealer. The clutch is a complex mechanism that rotates at high speeds. Each clutch is dynamically balanced
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 24
    SAFETY Operator Safety Driving Responsibly Every snowmobile handles differently, and even the most docile conditions may become dangerous if operators drive improperly. If you're new to snowmobiling, acquaint yourself with the snowmobile and with what it will and won't do under various conditions.
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 25
    SAFETY Operator Safety Windchill/Temperature Charts The following information is provided to help you determine when temperatures become dangerous for riding. WINDCHILL CHART (°F) Wind Speed 40 in MPH Calm 5 10 15 20 25 30 35 40 45 50 55 60 40 36 34 32 30 29 28 28 27 26 26 25 25 Actual Thermometer
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 26
    of the labels and other warnings on the snowmobile carefully. If any of the labels depicted in this manual differ from the labels on your snowmobile, always read and follow the instructions of the labels on the snowmobile. If any label becomes illegible or comes off, contact your POLARIS dealer
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 27
    backing up. • Avoid sharp turns. • Shift to or from reverse only when stopped. • Apply throttle slowly. NOTE: For more information, see Owner's Manual. If electric reverse: • Machine stopped and engine at idle, push yellow button on LH control to reverse. Flashing light on dash indicates reverse
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 28
    stop. • To maintain vehicle control on ice or hard-packed surfaces, you should have a proper balance of ski carbides to track studs. See Owner's Manual for proper use of traction products. • Repeated stops from high speed may cause fading or sudden loss of braking ability. • Parking brake may relax
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 29
    operate engine with the clutch guard removed. Never run engine with drive belt removed. Never service clutches yourself - See your dealer. Belt Removal - All Units 1. For electric reverse Clutch Warning/Belt Removal 2. 3. 4. Note: See owners manual for sheave width adjustment procedure. 7181093 27
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 30
    FEATURES 7 8 5 9 10 11 4 3 2 6 1 12 13 14 15 18 17 19 16 SWITCHBACK ADVENTURE (INTL) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 28 Nosepan Skis Front Bumper Hood Headlight Windshield (if equipped) Handlebar Operator Seat Taillight Rear Bumper 11. 12. 13. 14. 15. 16. Snow Flap Suspension Track Side Panel Side
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 31
    FEATURES 2 3 4 1 5 6 1. Brake Lever 2. Instrument Cluster (Interactive Digital Display shown) 3. Ignition Switch 4. Engine Stop Switch 5. Throttle Control 6. Recoil Starter Handle 7. Parking Brake Lock 8. Handlebar Grip Warmer Switch 9. Thumbwarmer Switch 10. POLARIS Electronic Reverse (PERC)
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 32
    FEATURES Adjustable Headlight The headlight can be adjusted for vertical aim using the following procedure. 25 ft. (7.6 m) Lamp Center Height X 2 in. (5 cm) 1. In a well-ventilated area, position the snowmobile on a level surface with the headlight approximately 25 feet (7.6 m) from a wall. 2.
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 33
    power plug RCA Power Plug with Cover (with cover) mounts to the handlebar cover and is plugged into the main vehicle wire harness. Installation instructions are provided with the accessory. This power point is powered by the load shed relay and is not fuse protected. POLARIS recommends using this
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 34
    FEATURES Lighting and Warmers Power Management The following components are always powered when the engine is running: • Low Beam Headlights • Taillights/Brake Lights • Passenger Hand Warmers (if equipped) The brake light is protected by a 2 amp mini fuse located in the protective bag above the
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 35
    FEATURES Battery Charge Relay Control Some models are equipped with a battery. The battery provides power for only two purposes: • Engaging the electric starter motor to start the engine • Powering the Polaris Interactive Digital Display (IDD) with the ignition key when the engine is off The engine
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 36
    FEATURES Saddlebags Some snowmobiles are equipped with saddlebags. LOCK & RIDE saddlebags can be added as an accessory on other models. Please see your POLARIS dealer for more information. Three (3) locking plungers secure each saddlebag to the rear cargo rack. To remove a saddlebag, open each
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 37
    a safeguard. Interactive Digital Display (IDD) If your model is equipped with the interactive digital display (IDD), please see your IDD Owner's Manual for fuel type selection procedures. Standard Instrument Cluster Fuel Selection Use the following procedure to change the fuel type designation in
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 38
    FEATURES Detonation Elimination Technology (DET) When DET senses and takes action to reduce detonation, the driver may notice a drop in engine RPM and/or reduced performance. The ECU will illuminate the check engine LED and display "dET" on the LCD screen whenever the DET system is active. If the
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 39
    causes of severe detonation are outlined in the troubleshooting table below. DET Troubleshooting Cause of DET Activation Poor quality fuel with recommended fuel Replace with recommended fuel See your POLARIS dealer for service Do not add deicers or additives that contain any form of alcohol
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 40
    when engine temperature reaches critical levels. Stop the engine immediately. Please see your IDD Owner's Manual for more information. 600/800 HO Models Engine Temperature Protection Modes Hot Lamp ON FLASHING Threshold* something other than poor cooling conditions, see your dealer for service. 38
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 41
    the snowmobile will not move when throttle is applied. If you wish to use this system, see page 47 for security system activation and operating instructions (standard instrument cluster). If your model is equipped with the Interactive Digital Display (IDD), please see the IDD Owner
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 42
    FEATURES Standard Instrument Cluster Rider Information Center Check Engine Indicator OverTemperature Indicator High Beam Indicator Parking Brake Indicator Low Oil Indicator MODE Button SELECT Button Reverse Indicator The instrument cluster contains indicator lights and the rider information
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 43
    the lights are set to high beam. Parking Brake Indicator This indicator illuminates when the parking brake is engaged. It will also illuminate when the service brake is in use. See page 80. Reverse Indicator This indicator flashes when the snowmobile is in reverse. See page 95. 41
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 44
    FEATURES Standard Instrument Cluster Rider Information Center The rider information center is located in the instrument cluster. The center displays vehicle speed, engine speed, odometer, resettable trip meters (2), total engine hours of operation, fuel level, engine temperature and diagnostic
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 45
    FEATURES Standard Instrument Cluster Rider Information Center 1. Information Display Area - This area displays either engine speed or vehicle speed (whichever is not displayed in the speed display), engine temperature and maximum vehicle speed. To change the display, see page 44. 2. Speed Display -
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 46
    FEATURES Standard Instrument Cluster Rider Information Center Speed Display Area The speed display area displays either vehicle speed or engine speed. Vehicle speed is displayed in either miles per hour (MPH) or kilometers per hour (km/h). Engine speed is displayed in revolutions per minute (RPM).
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 47
    FEATURES Standard Instrument Cluster Rider Information Center Odometer/Engine Hour Display Area This area displays the odometer, Trip A meter, Trip B meter and engine hours meter. The odometer displays the total distance traveled by the vehicle since manufacture. Each trip meter records the distance
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 48
    FEATURES Standard Instrument Cluster Rider Information Center Standard/Metric Display The odometer and temperature displays can be viewed in either standard or metric units of measurement. Both displays change if units are changed. The new settings will remain until changed by the operator. Change
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 49
    FEATURES Standard Instrument Cluster Rider Information Center Security System (Ignition Lock System) This system is an optional feature and will not function until it has been activated by your authorized POLARIS dealer. If you have this feature activated, you can lock the ignition to prevent
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 50
    FEATURES Standard Instrument Cluster Rider Information Center Security System (Ignition Lock System) First Time Use of Your Security System Perform all tasks in the order shown if you wish to activate and use the optional security system. TASK 1: Activate the security system See your authorized
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 51
    FEATURES Standard Instrument Cluster Rider Information Center Security System (Ignition Lock System) First Time Use of Your Security System TASK 3: Unlock the System 1. When the engine is running, the display will alternate between SECURE ON and ENTER CODE. Wait until ENTER CODE displays, then press
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 52
    FEATURES Standard Instrument Cluster Rider Information Center Security System (Ignition Lock System) Locking the System With Your Personal Security Code 1. Start the engine and lock the parking brake. 2. Press and hold the MODE and SEL buttons for 3 seconds, then release. SECURE OFF should be
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 53
    FEATURES Standard Instrument Cluster Rider Information Center Security System (Ignition Lock System) Unlocking the System With Your Personal Security Code 1. When the engine is running, the display will alternate between SECURE ON and ENTER CODE. Wait until ENTER CODE displays, then press and
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 54
    FEATURES Standard Instrument Cluster Rider Information Center Security System (Ignition Lock System) Changing to a New Security Code Any time you wish to change your current security code to a new code, perform TASK 2 through TASK 4 of the First Time Use of Your Security System procedure beginning
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 55
    FEATURES Standard Instrument Cluster Rider Information Center Diagnostic Display Mode The diagnostic display mode is for informational purposes only. Please see your POLARIS dealer for all major repairs. The diagnostic mode is accessible only when the check engine warning indicator is illuminated
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 56
    either the five button keypad on the IDD or by the MODE/SET switch on the left handlebar. MODE SET Please see your IDD Owner's Manual for more information. This manual is frequently updated for accuracy and new features. 1. 2. 3. 4. Go to: http://www.polaris.com/en-us/company/owners
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 57
    THE PERFECT FIT Suspension Quick Set-Up Guide Introduction The front suspension and PRO-XC rear suspension on your AXYS snowmobile is incredibly easy to adjust. Just remember three simple steps: 1. Ride your
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 58
    THE PERFECT FIT Suspension Quick Set-Up Guide Ride Experience Table Ride Experience Too "LITE" •Ski pressure is too light •Skis push Too much "BITE" •Ski pressure is too heavy •Steering is heavy
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 59
    THE PERFECT FIT Suspension Quick Set-Up Guide Shock Locations REAR TRACK SHOCK FRONT (IFS) SHOCKS FRONT TRACK SHOCK MORE LITE MORE BITE 57
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 60
    THE PERFECT FIT Suspension Quick Set-Up Guide Front Suspension (IFS) Factory Spring Settings Spring Setting Model Spring Rate Preload (Factory Setting) in 2-1/2 4-1/2 2-1/2 4-1/2 2-1/4 4-1/2 cm 6.4 11.4 6.4 11.4 5.7 11.4 Preload (Minimum Setting) in 2-1/2 4-1/2 2-1/2 4-1/2 2-1/4 4-1/2 cm 6.4 11.4
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 61
    THE PERFECT FIT Suspension Quick Set-Up Guide Front (IFS) Shock Adjustments SOFTER STIFFER LOWER E UR AS ME ALL PRO-S/PRO-X/SWITCHBACK ADVENTURE (INTL) MODELS SOFTER SOFTER STIFFER RUSH LTD (High Speed Adjustment)
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 62
    THE PERFECT FIT Suspension Quick Set-Up Guide Front Track Shock Factory Spring Settings Spring Setting Model Spring Rate Preload (Factory Setting) in cm 3.8 2.54 3.8 2.54 3.5 2.54 Preload (Minimum Setting) in 1-1/2 1 1-1/2 1 1-1/4 1 cm 3.8 2.54 3.8 2.
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 63
    THE PERFECT FIT Suspension Quick Set-Up Guide Front Track Shock Adjustments SOFTER MORE LITE MEASURE HERE STIFFER MORE BITE ALL MODELS EXCEPT SWITCHBACK ADVENTURE SOFTER STIFFER SWITCHBACK ADVENTURE 61
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 64
    THE PERFECT FIT Suspension Quick Set-Up Guide Rear Track Shock Factory Spring Settings Spring Setting Model Spring Rate Preload (Factory Setting) in 2.75 1.5 2.75 1.5 N/A 1.5 cm 7 3.8 7 3.8 N/A 3.8 Preload (Minimum Setting) in 2 .5 2 .5 N/A .5 cm 5 1.2 5 1.2 N/A 1.2 Preload (Maximum
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 65
    THE PERFECT FIT Suspension Quick Setup Guide Rear Track Shock Adjustments SOFTER MORE BITE STIFFER U AS RE HE RE MORE LITE ME ALL PRO-S/PRO-X/SWITCHBACK ADVENTURE (INTL) MODELS SOFTER SOFTER STIFFER
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 66
    THE PERFECT FIT Suspension Quick Setup Guide Rear Track Shock Air Pressure (SWITCHBACK ADVENTURE) The factory-installed air assist rear shock contains zero air pressure, which will provide an optimum ride when
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 67
    THE PERFECT FIT Suspension Quick Setup Guide Rear Track Shock Air Pressure (SWITCHBACK ADVENTURE) 4. Continue pumping to the desired pressure setting. NOTICE: Do not exceed 50 PSI (345 kPa). 5. To decrease pressure,
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 68
    THE PERFECT FIT Suspension Quick Setup Guide Limiter Strap Adjustment The front torque arm limiter strap is set at position #1. MORE BITE MORE LITE POLARIS recommends leaving the limiter strap length at
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 69
    THE PERFECT FIT Handlebar Adjustments Riser Angle Riser angle can be adjusted to suit rider preference. Factory settings are shown below. PRO-S Models - 0° PRO-X Models - 11° Forward 1. Loosen the four bolts on the bottom of the adjuster block. If necessary, pry the blocks apart with a screwdriver.
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 70
    THE PERFECT FIT Handlebar Adjustments Riser Height (RUSH LTD) 1. Release the riser clamp. 2. Adjust the handlebar upward or downward to the desired height. 3. Secure the riser clamp. Handlebar Riser Riser Clamp 68
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 71
    THE PERFECT FIT Handlebar Adjustments Handlebar Angle Handlebar angle can be adjusted to suit rider preference. Factory settings are shown below. PRO-S Models - 30° PRO-X Models - 30° 1. Loosen the four bolts on the top riser block. 2. Adjust the handlebar upward or downward to the desired angle.
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 72
    THE PERFECT FIT Handlebar Component Fastener Torques Shown with riser cover removed for clarity 3 7 6 1 2 4/5 3 Component Torque Do not over-tighten IMPORTANT: Moving a handlebar component without first loosening its screws/set screws may cut grooves into the handlebar, making it difficult to
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 73
    THE PERFECT FIT Left Hand Control Adjustment IMPORTANT: Moving the left hand control without loosening the four mounting screws will cause the housing locating pins to cut grooves into the handlebar. When this occurs, the left hand control may not clamp tightly to the handlebar. If the left hand
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 74
    THE PERFECT FIT Handlebar Component Locations Refer to the following illustration and measurements to position handlebar components at factory-specified locations. Handlebar Component Alignment Measurements 1. 2. 3. 4. 5. 6. .011 in. (3 mm) 6.65 in. (169 mm) 6.7 in. (170 mm) 10 in. (254 mm) .47 in
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 75
    THE PERFECT FIT Traction Products Studs NOTICE: Failure to heed the following recommendations will result in tunnel or track damage and a voided warranty. The track is not warranted by POLARIS if studs have been installed. Track warranties are also void if track damage or failure results from the
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 76
    THE PERFECT FIT Traction Products Studs Track studding will enhance braking control on hard-packed snow or ice, but extreme caution is still required on such surfaces. Steering ability may be reduced on hard-packed snow or ice. When studded tracks are used, increased wear to the brake pads will
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 77
    THE PERFECT FIT Traction Products Carbide Skags A skag is a replaceable bar attached to the underside of the ski to assist in turning the snowmobile and to prevent ski wear caused by contact with roads and other bare terrain. Use carbide skags with studded tracks to help maintain proper steering and
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 78
    PRE-RIDE INSPECTIONS Pre-Ride Checklist Inspect all items on the checklist for proper operation or condition before each use of the snowmobile. Procedures are outlined on the referenced pages. Item Drive Belt Condition Steering System Recoil Rope Coolant Level Chaincase Oil Level Injection Oil Level
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 79
    your snowmobile's reliability and cause needless repairs and down time. Before beginning any snowmobile trip, a visual inspection will uncover potential problems. Check the following items on a weekly basis or before any long trip. Item Check suspension mounting bolts for tightness. Check rear
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 80
    and Understand Your Owner's Manual Read the Owner's Manual completely and refer to it often. The manual is your guide to safe and enjoyable lever freeplay, DO NOT start the engine. Have the throttle serviced immediately. Throttle Release Switch Test the throttle release switch system before
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 81
    indicates low brake fluid level or air in the hydraulic system. Refer to the brake bleeding information on page 122 or see your dealer for service. 1/2" (1.3 cm) Lever Feel If the brake lever feels "spongy" when squeezed, check the brake fluid level and condition. Add fluid as needed. See page 121
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 82
    is in use. If the parking brake light does not come on when the parking brake or service brake is in use, have it serviced by your dealer. Lock Release To release the lock, squeeze the brake lever tightly. The lock will return to the unlocked position. WARNING! If the
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 83
    may interfere with the steering of your snowmobile, resulting in serious injury or death. Keep the underhood area free of snow and ice. Before driving, manually turn the skis to the left and right to be sure ice and snow are not interfering with full left and right steering. If difficulty
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 84
    PRE-RIDE INSPECTIONS Start the Engine and Check Before starting the engine, always refer to all safety warnings pertaining to snowmobile operation. Never engage the starter when the engine is running. Never start the engine without checking all vehicle components to be sure of proper operation. See
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 85
    OPERATION Ignition Switch The ignition switch has three positions. OFF RUN START Vehicle / IDD power off Vehicle / IDD power on Activates starter motor (if equipped) If equipped with electric start, turn the key to START to crank the engine. When the key is released, it automatically returns to the
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 86
    OPERATION Starting the Engine NOTICE: Engaging the starter when the engine is running WILL result in serious engine damage, especially if the snowmobile is in reverse. Never engage the starter when the engine is running. 1. Turn the key to the RUN position. 2. Pull the auxiliary engine stop switch
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 87
    OPERATION Break-In Period Engine Break-In The recommended break-in period is the time required to use the first full tank of pre-mixed fuel. Excessive heat build-up during the first three hours of operation will damage close-fitted engine parts. Do not operate at full throttle or high speeds for
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 88
    OPERATION Break-In Period Engine Break-In Never mix brands of oil. Serious chemical reactions can cause injection system blockage, resulting in serious engine damage. Oils may also be incompatible and the result could be sludge formation, filter blockage, and reduced cold weather flow rates. All
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 89
    behind it while warming up the track. Do not use excessive throttle during warm-up or when the track is free-hanging. Use a stable rear support. WARNING! Use of traction products such as studs will increase the possibility of track damage and/or failure. This could cause loss of control, resulting
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 90
    OPERATION Fuel WARNING Gasoline is highly flammable and explosive under certain conditions Always exercise extreme caution whenever handling gasoline. Always refuel outdoors or in a well-ventilated area. Always turn off the engine before refueling. Do not overfill the tank. Do not fill the tank
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 91
    OPERATION Fuel Recommendation For peak performance, POLARIS recommends the use of 91 octane fuel or higher. Although 87 octane fuel is usable, some engine performance will be lost and fuel economy will decrease. Do not use lower than 87 octane fuel. Do not use fuel containing more than 10% ethanol.
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 92
    OPERATION Oil Low Oil Level Always maintain the oil level between the "ADD" mark and the bottle neck. Do not fill the bottle neck. See page 85 for oil recommendations. 1. Immediately stop the engine if the low oil indicator light comes on. 2. Open the left side panel. See page 104. 3. View the oil
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 93
    OPERATION Auxiliary Engine Stop Switch Push the auxiliary engine stop switch down to ground out the ignition and stop the engine quickly. Pull the switch up to the RUN position to allow restarting. Stop Switch Throttle Release Switch The throttle release switch is designed to stop the engine if
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 94
    switch on and go through normal starting procedures. 5. If the engine doesn't start, take the snowmobile to an authorized POLARIS dealer for service. Throttle Lever Freeplay Inspection Throttle lever freeplay is the gap created between the throttle lever and throttle block, as you push the throttle
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 95
    OPERATION Throttle Lever Throttle Lever Freeplay Adjustment Adjust throttle lever freeplay using the in-line throttle cable adjuster. Lock Nut In-Line Adjuster 1. Locate the in-line adjuster on the throttle cable. 2. Loosen the lock nut. 3. Rotate the adjuster clockwise to DECREASE freeplay.
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 96
    OPERATION POLARIS Electronic Reverse Control (PERC) WARNING Improper reverse operation, even at low speeds, may cause loss of control, resulting in serious injury or death. Damage will occur to the chaincase if shifting is attempted when the engine is operating above idle speed. • Shift to or from
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 97
    OPERATION POLARIS Electronic Reverse (PERC) Engaging Reverse 1. Stop the snowmobile and leave the engine idling. 2. Make sure the area behind your vehicle is clear. 3. Push the yellow reverse button on the left-hand control for one second, then release. The engine will automatically reduce RPM and
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 98
    OPERATION Daily Storage At the end of each ride, park the snowmobile on a level surface and support it at the rear with an appropriate track stand. The track should be suspended approximately 4 inches (10 cm) off the ground. Remove the key and
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 99
    and it comes on, you must take your snowmobile to a qualified dealer for diagnostic service. Specifications and adjustments for engine tune-ups are located in the Service Manual, which is available to your qualified service technician. Reverse (if equipped) must not be engaged during engine tune-ups
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 100
    MAINTENANCE POLARIS Recommended Maintenance Program To ensure many trouble-free miles of snowmobiling enjoyment, follow recommended regular maintenance and perform service checks as outlined in this manual. Record maintenance and service in the Maintenance Log beginning on page 183. The recommended
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 101
    MAINTENANCE Periodic Maintenance Interval Table The following chart is a guide based on average riding conditions. You may need to increase frequency based on riding conditions. When inspection reveals the need for replacement parts, always use
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 102
    MAINTENANCE Periodic Maintenance Interval Table Item See Page Frequency 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi. (3200 km) PreSeason BRAKES Hose Routing Hose Condition Fluid Leaks Brake Pads Brake Disc Parking Brakes Brake System Brake Fluid Throttle Lever Fuel Lines Oil Lines
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 103
    MAINTENANCE Periodic Maintenance Interval Table Item See Page Frequency 150 mi. (240 km) 500 mi. (800 km) 1000 mi. (1600 km) 2000 mi. (3200 km) PreSeason CHASSIS Ski Toe Alignment Suspension Mounting Bolts Bolt Torques Steering Fasteners Rear Suspension Fasteners Suspension Shock Oil Rear Shock
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 104
    MAINTENANCE Diagnostic Display Code Definitions Open Load: There is a break in the wires that lead to the item listed in the chart (injector, fuel pump, etc.), or the item has failed. Short-to-Ground: The wire is shorted to ground between the electronic control unit and the item listed in the chart.
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 105
    MAINTENANCE Diagnostic Display Code Definitions Diagnostic Codes Component Knock Level Cylinder 1 (MAG) Condition Maximum Detonation Correction Limit Reached Knock Above Critical Level Maximum Detonation Correction Limit Reached Knock Above Critical Level Voltage Too Low Voltage Too Low Voltage Too
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 106
    MAINTENANCE Hood and Side Panels The hood and side panels protect the operator from moving parts. Never operate a snowmobile with the side panels open or removed. Always ensure that the hood and side panels are installed and securely latched before starting the engine. Side Panels (Opening/Removing
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 107
    MAINTENANCE Hood Removal and Installation 1. Remove the side panels. 2. Rotate the 1/4-turn fasteners at the upper corners of the hood. 3. Disconnect the wire harness leading to the console electronics. 4. Remove the hood assembly. 5. To reinstall the hood, slide the nose clips into the nosepan. 6.
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 108
    MAINTENANCE Tools The belt removal L-wrench tool and the spare belt, spark plug and spark plug tool container are located behind the left engine compartment panel. When properly engaged in the bracket, the L-wrench secures the fender to the console. To retrieve the L-wrench, rotate it counter-
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 109
    MAINTENANCE Tools 4. Pull the container out of the compartment. 5. When placing a drive belt into the container, fold the belt as shown. Verify that the belt loop at the rear of the container is positioned slightly higher than the front loop. Front Rear Step 4 Step 5 6. Slide the container into
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 110
    MAINTENANCE Rear Shock Body Lubricate rear shock body threads seasonally with a low-temperature synthetic grease. Driveshaft Bearing This model has sealed bearings that require no additional lubrication. Threads Chaincase Oil Check and change the chaincase oil at the intervals outlined in the
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 111
    MAINTENANCE Chaincase Oil Oil Change (Pump Method) NOTE: This procedure requires the use of a commercially available hand pump oil extractor. 1. Elevate the front of the snowmobile using a floor jack or appropriate lift. 2. Remove the fill plug. Clean all metal shavings off the plug. 3. Insert the
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 112
    MAINTENANCE Chaincase Oil Oil Change (Cover Drain Method) 1. Position the snowmobile on a level surface. 2. Remove the two screws securing the fender to the chaincase. 3. Remove the right side panel. If equipped with a battery, remove the battery/battery bracket assembly. See page 141. 4. Place a
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 113
    within the fuel tank. This filter should only require maintenance if debris or foreign material enters the fuel tank. See your POLARIS dealer for service. Contaminated or poor quality fuel may shorten the life of fuel system components and result in poor engine performance. Always store fuel in
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 114
    MAINTENANCE Intake Filters The intake foam filters limit snow ingestion into the intake system. When operating in loose powder snow, check the foam filters periodically to remove any accumulation of snow. Foam Filters 112
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 115
    MAINTENANCE Spark Plugs Spark Plug Recommendations A new engine can cause temporary spark plug fouling due to the preservative added during the assembly process. Avoid prolonged idle speeds, which cause plug fouling and carbonization. Change the spark plugs at the intervals outlined in the Periodic
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 116
    will be few combustion deposits. The electrodes are not burned or eroded. This indicates the proper type and heat range for the engine and the service. Wet Fouled Plug The wet fouled insulator tip is black. A damp oil film covers the firing end. There may be a carbon layer over the entire
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 117
    MAINTENANCE Cooling System Coolant The coolant supplied in the system at the factory is a 50/50 mixture of ethylene-glycol and distilled water, which will provide adequate freeze protection under most conditions. If the vehicle will be stored or operated at extremely low temperatures, greater
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 118
    maintains its ability to protect the engine, drain the system completely every five (5) years and add a fresh mixture of antifreeze and distilled water. This service must be performed when the engine is cold. Ask your POLARIS dealer to check the coolant when he performs the fall tune-up on your
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 119
    MAINTENANCE Cooling System Bleeding the Cooling System 6. Fill the coolant bottle to the COLD FILL mark. 7. Install the coolant bottle cap to the first lock. Do not tighten to the fully seated position. 8. Lock the parking brake. 9. Start the engine and allow it to run at a fast idle for several
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 120
    the side panels and remove the hood. 2. Inspect the muffler and pipes for cracks or damage. 3. Check for weak or missing retaining springs or damper/ support grommets. 4. Check for loose clamps on the pipe covers. 5. Reinstall the hood and side panels. Springs 118
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 121
    MAINTENANCE Drive Chain Tension Check drive chain tension at the intervals outlined in the Periodic Maintenance Table beginning on page 98. Check again before each long trip. CAUTION! Hot exhaust system parts can cause burns. Allow adequate time for the exhaust system to cool. Never perform this
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 122
    MAINTENANCE Brakes Hydraulic Brake Inspection Inspect brake lever travel before each use of the snowmobile. See page 79. Brake pads must be replaced when the brake pad material becomes thinner than the backing plate (approximately 1/16 inch or 1.5 mm). A kit is available for replacing brake pads.
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 123
    MAINTENANCE Brakes Brake Fluid Replace brake fluid at least every two years with POLARIS DOT 4 high temperature brake fluid. See page 149 for the part numbers of POLARIS products. WARNING! After opening a bottle of brake fluid, always discard any unused portion. Never store or use a partial bottle.
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 124
    MAINTENANCE Brakes Bleeding the Hydraulic Brake System Air in the hydraulic brake system will cause spongy brake lever action. Bleed the system before operating the snowmobile. WARNING! Operating the vehicle with a spongy brake lever can result in loss of brakes, which could cause an accident and
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 125
    MAINTENANCE Lights The headlight and taillight assemblies feature LED elements and are not serviceable. If an LED fails to illuminate in either the headlight or taillight, the entire assembly must be replaced. Please see your POLARIS dealer. Headlight Taillight 123
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 126
    MAINTENANCE Fuse Replacement If the engine stops or will not start, or if an electrical component fails to operate, a fuse may need replacement. Locate and correct any damage or short circuits that may have caused the blown fuse, then replace the fuse. NOTICE: Always replace a blown fuse with a new
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 127
    be damaged if lubricated. Do not lubricate clutch bushings. Clutch Alignment Offset Clutch alignment offset is important for maintaining optimum performance. See your dealer for service and adjustments. A special tool is required to check for proper alignment. 125
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 128
    for signs of excessive wear: frayed edges, missing cogs, cracks and excessive looseness. Replace the belt if any of these conditions exist. See Drive Belt Troubleshooting on page 174. Always carry a spare drive belt. Store the spare belt in the belt holder as shown. When placing the belt in the
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 129
    MAINTENANCE Clutch System Drive Belt Deflection Measure belt deflection with both clutches at rest and in their full neutral position. Place a straight edge (1) on the belt and apply downward pressure while measuring at point 2. This measurement should be 1 1/4 inches (3.2 cm). 2 1 Drive Belt
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 130
    MAINTENANCE Clutch System Drive Belt Removal NOTICE: Do not attempt to remove the drive belt after operating in reverse. The snowmobile must be stopped after forward motion to prevent damage to components during belt removal. Rotate the driven clutch counterclockwise 1/4 turn by hand to ensure
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 131
    MAINTENANCE Clutch System Drive Belt Installation 1. Verify the driven clutch sheaves are open. If they are not, install the L-wrench and open the sheaves. NOTE: When installing the belt, verify POLARIS or the part number can be read from the outside of the snowmobile. 2. Drop the drive belt over
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 132
    Never rotate a damaged track under power. 1. Using a hoist, safely lift and support the rear of the snowmobile off the ground. 2. Rotate the track by hand ! Operating with insufficient lubrication between the rail slide and track guide clips can cause track failure, loss of vehicle control and
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 133
    of the snowmobile for track adjustments. 2. Lift the rear of the snowmobile by the chassis (seat support, x-brace or running boards) until the track is slightly above the ground. Safely support the rear of the snowmobile in this position. 3. Place the recommended weight or downward pressure on the
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 134
    MAINTENANCE Track Maintenance Track Tension 5. Check for specified slack between the wear surface of the track clip and the plastic slider. Refer to the Track Tension Data Chart on page 131. If the track needs adjustment: 6. Loosen the rear idler shaft bolt. 7. Loosen the locknuts. Lock Nut Track
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 135
    check that the track is centered and running evenly on the slide rails. Misalignment will cause excessive wear to the track and slide rail. 1. Safely support the rear of the snowmobile with the track off the ground. 2. Start the engine and apply a small amount of throttle until the track turns
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 136
    . Each week, or before a long ride, check the following items. If component damage or loose fasteners are found, see your POLARIS dealer for service Upper / Lower control arms Spindles Fasteners (X in illustration) Skis, ski loops, ski stops, skags/carbides Tie rods, rod ends, tie rod boots Sway
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 137
    feels heavy, or if the snowmobile seems to pull or dart to the side, ski alignment may need adjustment. Refer to the service manual or see your dealer for this service. Ski Toe Settings WARNING! Improper ski toe adjustment may cause loss of steering control, resulting in serious injury or death. Do
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 138
    . TIP: Carbide skags must be replaced if any abnormal wear or chipping is found. Inspect carbide for damage or wear Ski Skag Replacement 1. Raise and support the front of the snowmobile so the skis are approximately 6 inches (15.2 cm) from the ground. 2. Remove the attaching nuts and pry the skag
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 139
    MAINTENANCE Front Suspension Control Arms Control Arm Pivot Adjustment The upper and lower control arms feature slotted pivots to allow for adjustment to compensate for bushing wear. NOTE: Upper control arm shown. Procedure is the same for lower control arm adjustment. 1. Loosen the four lock nuts.
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 140
    week, or before a long ride, check the following items. If component damage or loose fasteners are found, see your POLARIS dealer for service Rear crank / rear pivots Rear idler wheels / shaft Bogie / carrier wheels / shafts / fasteners Front torque arm Fasteners (X in illustration) Shocks Rail
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 141
    MAINTENANCE Rear Suspension Rail Slide Wear Measure slide thickness at several points along the rail. Have your dealer replace the slide when it's worn down to the top of the wear limit indicator groove. Do not operate the snowmobile if slide thickness measures less than 7/16 inch (1.1 cm). 7/16
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 142
    MAINTENANCE Battery (if equipped) WARNING! Improperly connecting or disconnecting battery cables can result in an explosion and cause serious injury or death. When removing the battery, always disconnect the negative (black) cable first. When reinstalling the battery, always connect the negative (
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 143
    MAINTENANCE Battery (if equipped) Battery Removal 7. Remove the fasteners (6) (7) securing the battery bracket to the chassis. 8. Pull the fender away from the battery compartment and remove the battery/battery bracket assembly. 9. Remove the battery holddown strap. 10. Remove the screw (4) securing
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 144
    has not been fully charged can damage the battery and result in a shorter life. It can also hinder vehicle performance. Follow the battery charging instructions on page 144 before installing the battery. 1. Place the fully charged battery in the battery bracket. 2. Place the battery shield on the
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 145
    MAINTENANCE Battery (if equipped) Battery Installation 8. Connect and tighten the black (negative) cable last. CAUTION! Verify the battery cables and wiring harness do not come into contact with the brake disc. Move the wiring harness/cables behind the chassis tube and away from the brake disc.
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 146
    the battery if the voltage drops below a pre-determined point. Battery Charging The following battery charging instructions apply only to the installation of a sealed battery. Read all instructions before proceeding with the installation of this battery. The sealed battery is already filled with
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 147
    or less until the battery voltage is 12.8 or greater. Tip: When using an automatic charger, refer to the charger manufacturer's instructions for recharging. When using a constant current charger, use the following guidelines for recharging. WARNING! An overheated battery may explode, causing severe
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 148
    MAINTENANCE Fall Tune-Up For maximum performance, arrange for a fall service tune-up with your POLARIS dealer. His experienced and trained service technician will keep your snowmobile in peak operating condition. Matte Clear Coat Cleaning (if equipped) Matte finish products are prone to trapping
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 149
    MAINTENANCE Cleaning and Preservation Proper storage starts with cleaning, washing, and waxing the hood, side panels, chassis, and plastic parts. Wipe down remaining surfaces with a damp cloth. Clean and touch up with paint any rusted or previously painted surfaces. Be sure that corrosive salt and
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 150
    shaft bushing as outlined in the Master Repair Manual. See your dealer. Engine Protection Proper preparation oil. Follow the engine fogging instructions provided on the container. Always add Carbon Clean during summer storage. The snowmobile should be supported off the ground to allow the track
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 151
    POLARIS PRODUCTS Part No. 2870791 2878243 2878191 2877882 2877953 2877883 2877884 2873105 2873106 2871312 2871322 2871423 2871329 2880514 2880513 2871326 2870652 2872189 2872893 2870505 Description Engine Lubricants Fogging Oil (12 oz. Aerosol) VES RACE 2-Cycle Engine Oil (qt./.95 l) VES RACE 2-
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 152
    SPECIFICATIONS 600 RUSH PRO-S Capacities and Dimensions Body Style Rider Capacity Coolant Capacity Chaincase Oil Capacity Fuel Tank Capacity Height Length Estimated Dry Weight Oil Capacity Designed Width Ski Center Distance Brake Type Fluid Drive Clutch Center Distance Drive Belt Type Projected
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 153
    SPECIFICATIONS 600 RUSH PRO-S Clutching Chart ALTITUDE Meters (Feet) 0-600 (0-2000) 600-1200 (2000-4000) 1200-1800 (4000-6000 1800-2400 (6000-8000) 2400-3000 (8000-10000) 3000-3600 (10000-12000) Drive Clutch Shift Weight Drive Clutch Spring Driven Clutch Spring Driven Helix Chaincase Gearing/
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 154
    SPECIFICATIONS 600 RUSH PRO-X (International) Capacities and Dimensions Body Style Rider Capacity Coolant Capacity Chaincase Oil Capacity Fuel Tank Capacity Height Length Estimated Dry Weight Oil Capacity Designed Width Ski Center Distance Brake Type Fluid Drive Clutch Center Distance Drive Belt
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 155
    SPECIFICATIONS 600 RUSH PRO-X (International) Clutching Chart ALTITUDE Meters (Feet) 0-600 (0-2000) 600-1200 (2000-4000) 1200-1800 (4000-6000 1800-2400 (6000-8000) 2400-3000 (8000-10000) 3000-3600 (10000-12000) Drive Clutch Shift Weight Drive Clutch Spring Driven Clutch Spring Driven Helix
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 156
    SPECIFICATIONS 600 SWITCHBACK PRO-S Capacities and Dimensions Body Style Rider Capacity Coolant Capacity Chaincase Oil Capacity Fuel Tank Capacity Height Length Estimated Dry Weight Oil Capacity Designed Width Ski Center Distance Brake Type Fluid Drive Clutch Center Distance Drive Belt Type
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 157
    SPECIFICATIONS 600 SWITCHBACK PRO-S Clutching Chart ALTITUDE Meters (Feet) 0-600 (0-2000) 600-1200 (2000-4000) 1200-1800 (4000-6000 1800-2400 (6000-8000) 2400-3000 (8000-10000) 3000-3600 (10000-12000) Drive Clutch Shift Weight Drive Clutch Spring Driven Clutch Spring Driven Helix Chaincase
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 158
    SPECIFICATIONS 600 SWITCHBACK PRO-X / ADVENTURE (International) Capacities and Dimensions Body Style Rider Capacity Coolant Capacity Chaincase Oil Capacity Fuel Tank Capacity Height Length Estimated Dry Weight Oil Capacity Designed Width Ski Center Distance Brake Type Fluid Drive Clutch Center
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 159
    SPECIFICATIONS 600 SWITCHBACK PRO-X / ADVENTURE (International) Clutching Chart ALTITUDE Meters (Feet) 0-600 (0-2000) 600-1200 (2000-4000) 1200-1800 (4000-6000 1800-2400 (6000-8000) 2400-3000 (8000-10000) 3000-3600 (10000-12000) Drive Clutch Shift Weight Drive Clutch Spring Driven Clutch Spring
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 160
    SPECIFICATIONS 600 SWITCHBACK ADVENTURE Capacities and Dimensions Body Style Rider Capacity Coolant Capacity Chaincase Oil Capacity Fuel Tank Capacity Height Length Estimated Dry Weight Oil Capacity Designed Width Ski Center Distance Brake Type Fluid Drive Clutch Center Distance Drive Belt Type
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 161
    SPECIFICATIONS 600 SWITCHBACK ADVENTURE Clutching Chart ALTITUDE Meters (Feet) 0-600 (0-2000) 600-1200 (2000-4000) 1200-1800 (4000-6000 1800-2400 (6000-8000) 2400-3000 (8000-10000) 3000-3600 (10000-12000) Drive Clutch Shift Weight Drive Clutch Spring Driven Clutch Spring Driven Helix Chaincase
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 162
    SPECIFICATIONS 800 RUSH PRO-S / LTD Capacities and Dimensions Body Style Rider Capacity Coolant Capacity Chaincase Oil Capacity Fuel Tank Capacity Height Length Estimated Dry Weight Oil Capacity Designed Width Ski Center Distance Brake Type Fluid Drive Clutch Center Distance Drive Belt Type
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 163
    SPECIFICATIONS 800 RUSH PRO-S / LTD Clutching Chart ALTITUDE Meters (Feet) 0-600 (0-2000) 600-1200 (2000-4000) 1200-1800 (4000-6000 1800-2400 (6000-8000) 2400-3000 (8000-10000) 3000-3600 (10000-12000) Drive Clutch Shift Weight Drive Clutch Spring Driven Clutch Spring Driven Helix Chaincase
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 164
    SPECIFICATIONS 800 RUSH PRO-X Capacities and Dimensions Body Style Rider Capacity Coolant Capacity Chaincase Oil Capacity Fuel Tank Capacity Height Length Estimated Dry Weight Oil Capacity Designed Width Ski Center Distance Brake Type Fluid Drive Clutch Center Distance Drive Belt Type Projected
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 165
    SPECIFICATIONS 800 RUSH PRO-X Clutching Chart ALTITUDE Meters (Feet) 0-600 (0-2000) 600-1200 (2000-4000) 1200-1800 (4000-6000 1800-2400 (6000-8000) 2400-3000 (8000-10000) 3000-3600 (10000-12000) Drive Clutch Shift Weight Drive Clutch Spring Driven Clutch Spring Driven Helix Chaincase Gearing/
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 166
    SPECIFICATIONS 800 SWITCHBACK PRO-S Capacities and Dimensions Body Style Rider Capacity Coolant Capacity Chaincase Oil Capacity Fuel Tank Capacity Height Length Estimated Dry Weight Oil Capacity Designed Width Ski Center Distance Brake Type Fluid Drive Clutch Center Distance Drive Belt Type
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 167
    SPECIFICATIONS 800 SWITCHBACK PRO-S Clutching Chart ALTITUDE Meters (Feet) 0-600 (0-2000) 600-1200 (2000-4000) 1200-1800 (4000-6000 1800-2400 (6000-8000) 2400-3000 (8000-10000) 3000-3600 (10000-12000) Drive Clutch Shift Weight Drive Clutch Spring Driven Clutch Spring Driven Helix Chaincase
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 168
    SPECIFICATIONS 800 SWITCHBACK ADVENTURE Capacities and Dimensions Body Style Rider Capacity Coolant Capacity Chaincase Oil Capacity Fuel Tank Capacity Height Length Estimated Dry Weight Oil Capacity Designed Width Ski Center Distance Brake Type Fluid Drive Clutch Center Distance Drive Belt Type
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 169
    SPECIFICATIONS 800 SWITCHBACK ADVENTURE Clutching Chart ALTITUDE Meters (Feet) 0-600 (0-2000) 600-1200 (2000-4000) 1200-1800 (4000-6000 1800-2400 (6000-8000) 2400-3000 (8000-10000) 3000-3600 (10000-12000) Drive Clutch Shift Weight Drive Clutch Spring Driven Clutch Spring Driven Helix Chaincase
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 170
    SPECIFICATIONS 800 SWITCHBACK PRO-X Capacities and Dimensions Body Style Rider Capacity Coolant Capacity Chaincase Oil Capacity Fuel Tank Capacity Height Length Estimated Dry Weight Oil Capacity Designed Width) Ski Center Distance Brake Type Fluid Drive Clutch Center Distance Drive Belt Type
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 171
    SPECIFICATIONS 800 SWITCHBACK PRO-X Clutching Chart ALTITUDE Meters (Feet) 0-600 (0-2000) 600-1200 (2000-4000) 1200-1800 (4000-6000 1800-2400 (6000-8000) 2400-3000 (8000-10000) 3000-3600 (10000-12000) Drive Clutch Shift Weight Drive Clutch Spring Driven Clutch Spring Driven Helix Chaincase
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 172
    TROUBLESHOOTING Engine Troubleshooting Unless you have experience and training in two-cycle engine repair, see your dealer if technical problems arise. Problem Erratic engine operating RPM during acceleration or load variations Harsh drive clutch engagement Probable Cause Solution Drive clutch
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 173
    TROUBLESHOOTING Engine Troubleshooting Problem Noise in drive system Probable Cause Solution Broken drive clutch components Bearing failure/ chaincase, jackshaft, or front drive shaft Drive belt surface flat spots Drive
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 174
    TROUBLESHOOTING Engine Troubleshooting Problem Engine turns but fails to start Probable fuel line, filter or pump. Add isopropyl alcohol to the fuel system. • This indicates a major engine problem that must be repaired before operating. SEE YOUR DEALER. • Replace the plug(s). • SEE YOUR DEALER. •
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 175
    TROUBLESHOOTING Suspension Troubleshooting Problem Rear suspension bottoms too easily Rides too stiff in rear Solution • Adjust rear track shock • Track tension too loose (see page 131). • Studs (if installed) are loose. Follow manufacturer's installation instructions and re-torque studs. 173
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 176
    Drive Belt Troubleshooting Belt Wear/Burn Diagnosis Causes Driving at low RPM Parking brake engaged Insufficient warm-up Solutions • Drive at higher RPMs. Gear the machine down. Check
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 177
    of purchase 5. Details of trouble experienced 6. Length of time and conditions of operation 7. Previous correspondence Use the page provided near the front of your owner's manual to record the identification numbers of your snowmobile and its engine. POLARIS Customer Service United States & Canada
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 178
    Two-year extended engine coverage • Two-year powertrain coverage • Extended service contract See your dealer for details and separate terms and conditions for and set-up of your vehicle is very important in ensuring trouble-free operation. Purchasing a machine in the crate or without proper dealer set
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 179
    WARRANTY Warranty Coverage and Exclusions Limitations of Warranties and Remedies This POLARIS Limited Warranty excludes any failures that are not caused by a defect in material or workmanship. THIS WARRANTY DOES NOT COVER CLAIMS OF DEFECTIVE DESIGN. This warranty also does not cover acts of God,
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 180
    WARRANTY Warranty Coverage and Exclusions Limitations of Warranties and Remedies Lubricants and Fluids 1. Mixing oil brands or using non-recommended oil may cause engine damage. We recommend the use of POLARIS engine oil. 2. Damage or failure resulting from the use of non-recommended lubricants or
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 181
    must be done by an authorized POLARIS dealer. If you move or are traveling within the country where your product was purchased, warranty and service bulletin repairs may be requested from any authorized POLARIS dealer that sells the same line as your product. Outside the country where your product
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 182
    where it was purchased and you have not followed the procedure set above, your product will no longer be eligible for warranty or service bulletin coverage of any kind, other than safety bulletins. Products registered to Government officials or military personnel on assignment outside of the country
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 183
    WARRANTY U.S.A. EPA Emissions Limited Warranty This Emissions Limited Warranty is in addition to the POLARIS standard Limited Warranty for your vehicle. POLARIS Industries Inc. warrants that at the time it is first purchased, this emissions-certified vehicle is designed, built and equipped so it
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 184
    responsible for performing the scheduled maintenance identified in the owner's manual. POLARIS may deny warranty claims for failures that have been recommends that you contact an authorized POLARIS dealer to perform any service that may be necessary for your vehicle. POLARIS also recommends that
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 185
    MAINTENANCE LOG Present this section of your manual to your dealer each time your snowmobile is serviced. This will provide you and future owners with an accurate log of maintenance and services performed on the snowmobile. DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 150 mi. (240 km)
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 186
    MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 184
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 187
    MAINTENANCE LOG DATE MILES (KM) TECHNICIAN SERVICE PERFORMED / COMMENTS 185
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 188
    ...137 Coolant...115 Coolant Level...115 Cooling System ...115-117 Cooling System, Bleeding ...116-117 Cooling System, Flushing ...116 Customer Service...175 F Fasteners, Side Panel ...81 Fluid Change Chaincase ...109-111 Coolant ...116 Fluid Level Brake Fluid ...121 Chaincase ...108 Coolant
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 189
    Lighting Power Management ...32 Lights ...123 Lights, Headlight/Taillight Service 123 M Maintenance Interval Table ...99-101 Maintenance Program Deep Snow...19 Operator Safety ...9-23 Overheating, Engine ...38-39 G Guide, Suspension Set-Up ...55-66 H Handlebar Adjustments...67-69 Handlebar Angle
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 190
    Pre-Ride ...77 Suspension Inspection, Rear ...138 Suspension Quick Set-Up Guide . 55-66 Suspension, Rear ...138-139 Switches Engine Stop Switch... Transporting the Snowmobile ...148 Troubleshooting, Drive Belt ...174 Troubleshooting, Engine ...170-172 Troubleshooting, Suspension...173 Tune-Up...146
  • 2016 Polaris 800 Rush PRO-S | Owners Manual - Page 191
    For your nearest Polaris dealer, call 1-800-POLARIS (765-2747) or visit www.polaris.com Polaris Industries Inc. 2100 Hwy. 55 Medina, MN 55340 Part No. 9925998 Rev 01 Printed in USA
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Snowmobile Owner's Manual
for Maintenance and Safety
600 RUSH
800 RUSH
600 SWITCHBACK
800 SWITCHBACK