POLARIS RUSH 2010 (01) PDF Document

You can find the identification numbers for your POLARIS RUSH 2010 in the following locations:

Vehicle Model Number: Varies by model.

Tunnel VIN: Located on the right side of the tunnel.

Engine Serial Number: Located on the recoil housing.

It is recommended to record these numbers, along with your key number, in your owner’s manual for future reference.

When operating your POLARIS RUSH 2010, always adhere to the following safety precautions:

Alcohol and Drugs: Never drink alcohol or use drugs or medications before or while driving. They reduce alertness and slow reaction time.

Modifications: Do not modify your machine, especially with modifications that increase speed or power. The snowmobile may become aerodynamically unstable at speeds higher than it was designed for, leading to loss of control. The warranty is terminated if any equipment has been added or modifications have been made to increase speed or power.

Stay Clear of Track: The snowmobile is propelled by a revolving track. Serious injuries can result if hands, feet, or clothing become entangled. Remain properly seated to stay clear of the track and never stand behind it while warming it up.

Stay Clear of Engine: Always stop the engine before attempting adjustments. Serious injury can occur if fingers or clothing contact moving engine parts.

Riding Position: The proper riding position is seated with both feet on the running boards and both hands on the handlebar grips for proper throttle, brake, and steering control.

Proper riding apparel is essential for safety and comfort when riding your POLARIS RUSH 2010.

Helmet: 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. Approved helmets in Europe, Asia, and Oceania bear an ECE 22.05 label.

Eye Protection: Always wear shatterproof goggles or use a shatterproof helmet face shield. Do not depend on eyeglasses or sunglasses for eye protection.

Clothing: Be prepared, warm, and comfortable. Be aware of the weather forecast, especially the windchill, and dress accordingly. Avoid wearing loose clothing or long scarves, which can become entangled in moving parts.

For your safety, always ride in a group and inform someone of your route and expected return time. If you must travel into remote areas, carry survival equipment appropriate for the conditions. Recommended items to carry on your POLARIS RUSH 2010 include:

Required Items:

• Spare Drive Belt

• Extra Set of Spark Plugs

• Tow Rope

• Extra Oil

• Fuel Deicer

• Winter Survival Kit

• Trail Map

• First Aid Kit

• Tool Kit

General Survival Equipment:

• Extra clothing

• Sleeping bag

• Flashlight

• Food and water

• Signaling mirror

• A means of building a fire

• A two-way radio or cellular telephone

Slippery Surfaces: Never attempt an abrupt change of direction on slippery surfaces like ice or hard-packed snow. Proceed slowly and use extra caution, as steering and braking control are reduced.

Inadequate Snow Conditions: Adequate snow cover is required for slide rail lubrication and engine cooling. Driving in too little snow can cause overheating and excessive wear to the slide rail, track, and/or engine. Reduce speeds and frequently drive into fresh snow to allow for cooling.

Deep Snow: If you get stuck, clear snow from the running board area. Step down the snow in front of the snowmobile so it can climb up and over when the throttle is opened.

Driving Downhill: Shift your weight to the rear of the snowmobile and reduce your speed. Apply just enough throttle to keep the clutch engaged, allowing engine compression to help slow the vehicle. Pump the brakes on long downhill stretches to avoid overheating.

Hilly Terrain: Use extra caution. If climbing a hill, keep your weight low and forward. If crossing a slope, keep your weight on the uphill side to maintain balance. If you cannot continue up a hill, turn the snowmobile downhill before it loses momentum.

The windchill charts help you determine when temperatures become dangerous for riding. Find the current air temperature at the top of the chart and the wind speed (your riding speed) on the left side. The intersection of these two values gives you the equivalent temperature, which is the effective temperature on exposed skin. The chart also indicates the approximate time it takes for frostbite to occur at different temperature ranges.

WINDCHILL CHART (°F)

Wind Speed in MPH	Actual Thermometer Reading (°F)
	40	30	20	10	0	-10	-20	-30	-40	-45
Calm	40	30	20	10	0	-10	-20	-30	-40	-45
5	36	25	13	1	-11	-22	-34	-46	-57	-63
10	34	21	9	-4	-16	-28	-41	-53	-66	-72
15	32	19	6	-7	-19	-32	-45	-58	-71	-77
20	30	17	4	-9	-22	-35	-48	-61	-74	-81
Frostbite in >> 30 min. | 10 min. | 5 min.

WINDCHILL CHART (°C)

Wind Speed in KPH	Actual Thermometer Reading (°C)
	5	-1	-7	-13	-19	-25	-31	-37	-43	-46
Calm	5	-1	-7	-13	-19	-25	-31	-37	-43	-46
8	3	-4	-11	-18	-25	-32	-39	-46	-53	-57
16	2	-6	-13	-21	-28	-36	-43	-50	-58	-62
24	1	-7	-15	-22	-30	-38	-45	-53	-61	-65
32	0	-8	-16	-24	-32	-39	-47	-55	-63	-67
Frostbite in >> 30 min. | 10 min. | 5 min.

To adjust the headlight beam on your POLARIS RUSH 2010, use the headlight adjuster switch. Move the adjuster to the left to raise the headlight beam upward. Move the adjuster to the right to lower the headlight beam downward.

The DET system on your POLARIS RUSH 2010 prevents engine damage from detonation by activating an engine protection mode. The check engine light will indicate the level of detonation detected.

Check Engine Light	Indicates
Off	Mild detonation may be detected
Solid or Flickering	Excessive detonation detected
Steady Flashing	Severe detonation detected, RPM will be limited

If excessive detonation occurs, the check engine light will be solid or flicker, and you may notice decreased performance. This is usually temporary. If severe detonation occurs, the light will flash steadily, the gauge will read “dET”, and the engine will enter a “limp home” mode with RPM limited to 6500. This mode remains until the engine is shut down and restarted.

DET Troubleshooting

Cause of DET Activation	Solution
Poor quality fuel	Replace with higher quality fuel
Incorrect ethanol/non-ethanol fuel resistor installed	Verify correct fuel resistor for fuel type in tank
Low fuel/no fuel in tank	Refuel with recommended fuel
Water in fuel	Replace with recommended fuel
Alcohol-based fuel additive used with Ethanol fuel	Do not add deicers or additives that contain any form of alcohol while using up to 10% ethanol fuel

The instrument cluster on your POLARIS RUSH 2010 provides vital information through indicator lights and a rider information center. You can control the display using the MODE and SELECT buttons on the cluster or the MODE/SET switch on the left handlebar.

Indicators:

• Check Engine: Appears if an EFI-related fault occurs. Do not operate the snowmobile if this is on.

• Over-Temperature: Illuminates when the engine is overheating. Flashes for critical overheating.

• Low Oil: Appears when engine oil is too low. Stop the engine immediately and add oil.

• High Beam: Illuminates when high beams are on.

• Parking Brake: Illuminates when the parking or service brake is in use.

• Reverse: Flashes when the transmission is in reverse.

Rider Information Center:

• Information Display Area: Displays engine speed (RPM), vehicle speed (MPH or km/h), engine temperature, and maximum vehicle speed. Press and release the MODE button to cycle through items.

• Speed Display: Shows either vehicle speed or engine speed. Press and hold the MODE button for three seconds to switch between them.

• Fuel Gauge: Shows fuel level. When the last segment clears, the icon flashes, indicating low fuel.

• Odometer/Engine Hour Display: Shows total distance (odometer), Trip A, Trip B, and engine hours. Press and release the SELECT button to cycle through. To reset a trip meter, press and hold the SELECT button.

• Standard/Metric Display: To change units, navigate to either the engine temperature or odometer display. Then, press and hold the corresponding MODE or SELECT button until the units change.

You can view active diagnostic codes on your POLARIS RUSH 2010 only when the check engine warning indicator is illuminated. Follow these steps:

Step 1. Do not stop the engine.

Step 2. Press and release the SELECT button or SET switch to toggle to the diagnostic display mode, which appears after the engine hour display.

Step 3. The display will show two numbers: a 2-6 digit Suspect Parameter Number (SPN) in the main display area and a 1-2 digit Failure Mode Indicator (FMI) in the odometer area.

Step 4. If more than one fault is active, press and hold the MODE button for two seconds to toggle to the next active code.

Refer to the diagnostic code tables to understand the specific fault.

The diagnostic codes on your POLARIS RUSH 2010 consist of a Suspect Parameter Number (SPN) and a Failure Mode Indicator (FMI). These codes help identify specific issues with the vehicle’s electronic systems.

Component	Condition	SPN	FMI
Throttle Position Sensor	Voltage Too High	51	3
	Voltage Too Low		4
	Abnormal Rate of Change		10
Engine Temperature Sensor	Voltage Too High	110	3
	Voltage Too Low		4
	Temperature Too High		16
Intake Air Temperature Sensor	Voltage Too High	105	3
	Voltage Too Low		4
Crankshaft Position Sensor	Circuit Fault	636	8
	Plausibility Fault		2
Injector 1 (MAG) (SDI Part Load)	Driver Circuit Open/Grounded	651	5
	Driver Circuit Short to B+		3
Injector 2 (PTO) (SDI Part Load)	Driver Circuit Open/Grounded	652	5
	Driver Circuit Short to B+		3
Ignition Coil Primary Driver 1 (MAG)	Driver Circuit Open/Grounded	1268	5
Fuel Pump Driver Circuit	Driver Circuit Open/Grounded	1347	5
ECU Memory	Checksum/CRC Error	628	13

The suspension on your POLARIS RUSH 2010 is easy to adjust for your weight and riding style. Follow these three simple steps:

Step 1: Set up rear shock spring preload for rider weight.

Before your first ride, use the supplied gauge to adjust the rear spring preload. Position the narrow end of the gauge flush with the spring retainer. Turn the spring until your weight setting on the gauge aligns with the silver/red junction on the shock body.

Step 2: Adjust the rear spring to tune vehicle balance.

After an initial test ride, adjust the rear shock spring to improve balance. To correct too much weight transfer (light ski pressure), turn the spring retainer clockwise. To correct too little weight transfer (heavy steering), turn the spring retainer counter-clockwise.

Step 3: Adjust shock clickers for ride quality.

Adjust the shock clickers to control bottoming. Turning a clicker clockwise increases damping for a stiffer ride. Turning it counter-clockwise decreases damping for a softer ride. Adjust based on your riding experience:

Ride Experience	Clicker to Adjust	Adjustment
Bottoming in the IFS	IFS shock (after 150 mi. break-in)	Clockwise
Bottoming in the center	Front track shock	Clockwise
Bottoming in the rear	Rear shock	Clockwise
Harsh in chatter/bumps	Rear shock	Counter-clockwise

The following are the standard factory suspension settings for the POLARIS RUSH 2010. These settings are a good starting point for most riders.

Factory Suspension Settings

IFS and Front Track Shock
IFS Shock Clicker	6 clicks clockwise from full soft
IFS Shock Spring Preload	3 3/4″ (9.5 cm) from body end to retainer
Front Track Shock Clicker	2 clicks clockwise from full soft
Front Track Shock Spring Preload	1 1/4″ (3.2 cm) from body end to retainer

Stock 190 Rear Spring
Rear Shock Clicker	4 clicks clockwise from full soft
Rear Shock Spring Preload	See Optional Spring Guide (page 40 of PDF)

Allow the suspension to break in for about 150 miles (240 km) before making adjustments. Adjust one setting at a time and test ride under similar conditions.

IFS Shock Spring Preload:

Increasing preload increases ski-to-ground pressure. Decreasing it reduces pressure. The initial setting is 3 3/4 inches (9.5 cm) from the shock body end to the spring retainer. To adjust, grasp the spring retainer and rotate it. Ensure both left and right springs are at the same adjustment. Do not exceed one inch of preload beyond the factory setting.

IFS Shock Compression Damping:

Adjust the shock clickers to control bottoming. The standard setting is 6 clicks from the softest position. Turn the clicker clockwise for a stiffer ride and counter-clockwise for a softer ride. Adjust in 1-to-2-click increments and test ride.

Front Track Shock Compression Damping:

The standard clicker setting is 2 clicks from the softest position. Turn clockwise for a stiffer ride to control bottoming. Turn counter-clockwise for a softer ride. Adjust in 2-click increments.

Front Track Shock Spring Preload:

The initial setting is 1 1/4 inches (3.2 cm) from the body end to the retainer. Increasing preload will decrease ski-to-ground pressure. To adjust, grasp the spring retainer and rotate it.

Rear Shock Spring Preload Settings:

Adjust this spring to tune vehicle balance. Increasing preload increases ski pressure for flatter cornering. Decreasing preload decreases ski pressure for more weight transfer during acceleration. Adjust in one-turn increments from the initial setting and test ride.

Rear Shock Clicker:

The standard setting is 4 clicks from the softest position. Turn clockwise for a stiffer ride to control bottoming and chatter. Turn counter-clockwise for a softer ride. Adjust in 2-click increments.

You can adjust both the position and angle of the handlebars on your POLARIS RUSH 2010.

Handlebar Position (Forward/Rearward):

Step 1. Loosen the four bolts on the bottom of the adjuster block.

Step 2. Adjust the handlebar forward or rearward to the desired position.

Step 3. Tighten the bolts.

Handlebar Angle:

Step 1. Loosen the four bolts on the top of the adjuster block.

Step 2. Adjust the handlebar angle to the desired position.

Step 3. Tighten the bolts.

Before each use of your POLARIS RUSH 2010, inspect the following items for proper operation or condition:

Item	Check For
Drive Belt	Condition
Steering System	Proper Operation
Recoil Rope	Wear
Coolant Level	Proper Level
Chaincase Oil Level	Proper Level
Injection Oil Level	Proper Level
Parking Brake Lock/Brake System	Proper Operation
Engine Stop Switch	Proper Operation
Ignition Switch	Proper Operation
Headlight/Taillight/Brakelight	Proper Operation
Suspension Mounting Bolts	Tightness
Skags (Wear Bars)	Condition
Hood and Side Panel Fasteners	Secure
Throttle Lever/Safety Switch	Proper Operation
Rear Wheel Idler Bolts	Tightness
Track	Alignment/Condition
Rail Slide	Condition

Follow these steps to start your POLARIS RUSH 2010:

Step 1. Turn the key to the ON position.

Step 2. Pull the engine stop switch up to the RUN position.

Step 3. If equipped with electric start, turn the key to START to crank the engine. Release the key to ON when it starts.

Step 4. If not equipped with electric start, grasp the starter handle, pull slowly until the recoil engages, then pull abruptly.

Step 5. If the engine does not start after several attempts, slightly depress the throttle (no more than 1/4″ open) while cranking. Immediately release the throttle when the engine starts.

Restarting a Flooded Engine:

Step 1. Push the engine stop switch down to OFF.

Step 2. Turn the key to OFF.

Step 3. With both switches OFF, squeeze and hold the throttle in the wide-open position.

Step 4. Crank the engine several times to clear it.

Step 5. Release the throttle and restart using the normal procedure.

Proper engine break-in is crucial for the longevity of your POLARIS RUSH 2010.

Fuel/Oil Premix: Premix the first tank of fuel with one pint of Polaris injection oil for each five gallons of fuel. This is in addition to the lubrication from the oil injection system.

Operation: During the first three hours of operation, avoid operating at full throttle or high speeds for extended periods. Vary the throttle openings and vehicle speeds to allow the close-fitted machined parts to break in slowly without damage from excessive heat.

Lubricants: Polaris recommends using Polaris Semi-Synthetic Oil for the first tank premix and the first fill of the oil tank. Afterward, use of VES Gold Plus Synthetic 2-cycle oil is recommended. Never mix brands of oil.

Checks: Perform regular checks on fluid levels, lines, and all other important areas during the break-in period.

For peak performance, Polaris recommends the use of 91 octane fuel or higher. While 87 octane fuel is usable, some engine performance will be lost and fuel economy will decrease. Do not use fuel lower than 87 octane. Do not use fuel containing more than 10% ethanol. Never use E85 fuel in your snowmobile.

Your snowmobile is equipped with a fuel resistor to select the proper operating software based on the fuel type. The factory-installed resistor (“10% ETHANOL 24 OHM”) is for fuel with up to 10% ethanol. If you use non-ethanol fuel, install the resistor labeled “NON-ETHANOL 160 OHM” provided in the tool kit.

Test the throttle safety switch system daily before operation to ensure it is working correctly. A faulty switch can result in serious injury or death in the event of a throttle system malfunction.

Step 1. Sit on the seat.

Step 2. Start the engine and allow it to idle.

Step 3. Hold the throttle lever pivot pin stationary by exerting pressure on it.

Step 4. Apply a slight amount of throttle. A properly functioning switch must shut down the engine.

If the switch does not shut off the engine, immediately push down the engine stop switch. Do not start the engine again until the malfunction has been corrected by your dealer.

The electronic reverse will only activate if the engine RPM is below 4000.

Engaging Reverse:

Step 1. Stop the snowmobile and leave the engine idling.

Step 2. Ensure the area behind your vehicle is clear.

Step 3. Push the yellow reverse button on the left-hand control for one second, then release. The engine will reduce RPM and start a reverse rotation. A flashing reverse light on the instrument panel will indicate reverse is active.

Step 4. Apply the throttle slowly to confirm the transmission is in reverse. Maximum engine RPM is 6000 in reverse.

Disengaging Reverse:

Step 1. Stop the snowmobile and leave the engine idling.

Step 2. Push the yellow reverse button for one second and release. The engine will slow and begin to rotate forward. The reverse indicator light will shut off.

Step 3. Apply the throttle slowly to make sure the transmission is in forward.

Regular maintenance is key to the performance and longevity of your POLARIS RUSH 2010.

Chaincase Oil: Check and change the chaincase oil at recommended intervals. Maintain the oil level at the top of the fill plug hole. To change, remove the drain plug, let the oil drain completely, clean the plug, reinstall it, and then fill with 9 oz. (266 ml) of Polaris Synthetic Chaincase Lube until it begins to overflow from the fill hole.

Rear Shock Body Threads: Lubricate seasonally with Polaris Shock Thread Lubricant.

Driveshaft Bearing: Inject grease into the fitting on the speedometer sensor housing until grease purges from the seal on the inside of the tunnel (approximately two pumps).

Throttle Cable: Lubricate the cable lightly with grease or oil. With the engine off, turn the handlebars to the left and lubricate.

Drive Chain Tension: Check weekly. Rotate the driven clutch counter-clockwise to move slack to the tensioner side. Loosen the adjuster bolt jam nut. Finger-tighten the adjuster bolt until it stops, then back it off 1/4 turn. Tighten the jam nut while holding the adjuster bolt.

Always stop the snowmobile after forward motion before removing the belt. Do not attempt removal after operating in reverse.

Drive Belt Removal:

Step 1. Stop the engine and wait for it to come to a complete stop. Lock the parking brake.

Step 2. Remove the left side panel and open the clutch guard.

Step 3. Rotate the driven clutch counter-clockwise 1/4 turn by hand to ensure forward engagement.

Step 4. Locate the L-wrench in the tool kit. Install it into the open threaded hole in the outer sheave of the driven clutch.

Step 5. Turn the wrench clockwise to open the sheaves far enough to remove the belt.

Step 6. Firmly grasp the belt midway between the clutches and pull upward and rearward to remove it.

Drive Belt Installation:

Step 1. Drop the new drive belt over the drive clutch and pull back the slack.

Step 2. Turn the driven clutch’s moveable sheave clockwise while pushing inward and forcing the belt down between the sheaves.

Step 3. Hold the belt down and roll the bottom portion over the outer clutch sheave, working it to the outer edge.

Step 4. Remove the L-wrench (this will tighten the sheaves) and store it in the tool kit.

Step 5. Close the clutch guard and reinstall the side panel.

Proper track tension and alignment are critical for handling.

Track Tension Check:

Step 1. Turn the engine off and safely support the rear of the snowmobile off the ground.

Step 2. Place a 10 lb. (4.54 kg) weight on the track 16″ (40 cm) ahead of the center of the rear idler shaft.

Step 3. Measure the slack between the wear surface of the track clip and the plastic slider. It should be 7/8″ to 1 1/8″ (2.2-2.9 cm).

Track Tension Adjustment:

Step 1. Loosen the rear idler shaft bolts and the locknuts on the adjusting screws.

Step 2. Tighten or loosen the track adjusting screws equally on both sides to achieve the correct slack.

Step 3. After adjustment, tighten the locknuts and torque the idler shaft bolts to 35 ft. lbs. (47.5 Nm).

Track Alignment:

Step 1. Safely support the rear of the snowmobile off the ground.

Step 2. Start the engine and slowly rotate the track for at least five revolutions. Let it come to a stop without using the brakes.

Step 3. Inspect the track alignment by looking through the track window to see if the slide rails are evenly spaced from the track clips. If the track runs to the left, loosen the left locknut and tighten the left adjusting bolt. If it runs to the right, loosen the right locknut and tighten the right adjusting bolt.

Step 4. Repeat the process until the track is centered.

Proper off-season storage will prevent deterioration and prolong the life of your POLARIS RUSH 2010.

Cleaning and Preservation: Clean, wash, and wax the hood, side panels, and chassis. Ensure corrosive salt and acids are removed. Store in a dry garage or shed, out of direct sunlight, and cover with a fabric snowmobile cover (not a plastic tarp, which can cause condensation).

Controls and Linkage: Lubricate all bushings and cables as outlined in the periodic maintenance table.

Clutch and Drive System: Remove the drive belt and store it in a cool, dry location.

Engine Protection: For storage longer than 60 days, the engine must be fogged with fogging oil. Add a fuel conditioner/stabilizer (like Premium Carbon Clean) to the fuel tank, run the engine for five minutes to circulate it, then top off the tank with fresh fuel. Do not allow the snowmobile to run out of fuel.

Track and Suspension: Maintain moderate track tension and support the snowmobile off the ground to allow the track to hang freely.

Problem	Probable Cause	Solution
Harsh drive clutch engagement	Drive belt worn or too narrow	Replace the drive belt.
Drive belt turns over	Wrong belt for application	Replace the drive belt.
Machine fails to move	Track jammed	A foreign object may be caught, or the rail slide may have melted to the track clips due to lack of lubrication.
		The track may be iced up or frozen to the ground.
Poor low RPM performance	Poor fuel quality	Use 87-91 octane fuel (or higher).
Engine turns but fails to start	Faulty ignition	Install a new spark plug(s).
	No fuel to engine	Make sure the fuel valve is on and the tank contains fuel. Check for ice in the fuel line, filter, or pump.
Engine lacks power	Fouled or defective spark plug(s)	Replace the plug(s).
Engine continually backfires	Fuel System	Dirt or ice may be in the fuel system. Add deicer to non-ethanol fuel.

Problem	Solution
Rear suspension bottoms too easily	Adjust the rear shock spring.
Rides too stiff in rear	Check for binding suspension shafts and grease all pivot points. Adjust the rear shock spring.
Too much weight transfer when climbing	Adjust the rear shock spring.
Machine darts from side to side	Check ski alignment. Ensure spindles turn freely. Ensure skags are straight on skis. Check rail slide condition.
Front end pushes	Check for worn skags. Adjust the rear shock spring. Increase IFS preload.
Steering is heavy	Make sure spindles and steering components turn freely. Check ski alignment. Check skags and skis for damage. Adjust the rear shock spring.

Causes	Solutions
Driving at low RPM	Drive at higher RPMs. Gear the machine down. Check belt deflection.
Insufficient warm-up	Warm the engine for at least five minutes. In extremely cold weather, remove the belt and warm it up. Break the snowmobile loose from the snow before driving.
Towing at low RPM	Do not tow in deep snow. Use a fast, aggressive throttle to engage the clutch.
Riding with high RPM and slow speed	Lower the gear ratio. Reduce RPM. Avoid riding in high ambient temperatures. Check for snow ingestion.
Poor engine performance	Check for fouled plugs and water, ice, or dirt in the fuel tank or fuel line.
Slow, easy clutch engagement	Use a fast, aggressive throttle to engage the clutch.