Snowmobile Polaris 600 RUSH, 600 RUSH PRO-R, 800 RUSH, 800 RUSH PRO-R (2013 year). Manual - part 21

86

MAINTENANCE

Lubrication

Chaincase Oil

Check and change the chaincase oil at the intervals outlined in the main-
tenance charts beginning on page 81. Maintain the oil level at the top of 
the fill plug hole. POLARIS recommends the use of POLARIS Syn-
thetic Chaincase Lube. See page 115 for the part numbers of POLARIS 
products.

Oil Level

1. Position the vehicle on a level 

surface.

2. Remove the fill plug.

3. Using a funnel, slowly add the 

recommended oil until the fluid 
begins to overflow.

4. Wipe the fill area with a clean 

cloth.

5. Reinstall the fill plug. Torque to 

6-10 ft. lbs. (8-13 Nm). 

Oil Change 

1. Position the vehicle on a level surface.

2. Place a drain pan under the drain plug. Remove the drain plug. 

Allow the oil to drain completely.

3. Clean off all metal shavings from the plug.

TIP: The sealing surfaces on the drain plug and the oil tank should be clean and 

free of burrs, nicks or scratches.

4. Reinstall the drain plug. Torque to 6-10 ft. lbs. (8-13 Nm).

5. Remove the fill plug. Clean off all metal shavings from the plug.

6. Using a funnel, slowly add the recommended oil until the fluid 

begins to overflow. Fluid capacity is 9 oz. (266 ml).

7. Wipe the fill area with a clean cloth.

8. Reinstall the fill plug. Torque to 6-10 ft. lbs. (8-13 Nm).

Fill Plug

87

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.

Fuel Pump

All fuel pump service must be 
performed by an authorized 
POLARIS dealer. Do not 
attempt to service the fuel 
pump.

Fuel Filter/Fuel Lines

See your POLARIS dealer for replacement of the fuel filter at the inter-
vals outlined in the Periodic Maintenance Table beginning on page 81.

Contaminated or poor quality fuel will shorten the life of the fuel filter 
and result in poor engine performance. Always store fuel in clean fuel 
containers. If low fuel pressure or reduced engine performance occurs 
between the recommended fuel filter service intervals, the filter may 
need replacement. See your dealer.

Inspect the fuel lines regularly for signs of deterioration or damage. 
Always check fuel line condition after periods of storage. Normal dete-
rioration from weather and fuel compounds may occur. Replace worn or 
damaged fuel lines promptly.

NOTICE: Kinking the fuel lines or using a pliers or similar tools to remove fuel 

lines may cause damage to the lines. If a fuel line has been damaged 
or kinked, replace it promptly.

Foam Filters

88

MAINTENANCE

Spark Plugs

Spark Plug Recommendations

A new engine can cause temporary spark plug fouling due to the preser-
vative 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 Mainte-
nance Table beginning on page 81. Refer to the specifications section 
for the specific spark plug to be used in your snowmobile.

• Use recommended spark plugs with the proper gap.
• Use only resistor-type spark plugs.
• Torque spark plugs to 18-22 ft. lbs. (24-30 Nm).
• Always carry spare spark plugs.

NOTICE: Using non-recommended spark plugs can result in serious engine 

damage. A spark plug with a heat range too high will always cause 
engine damage if the engine is operated in conditions more severe 
than intended for that plug. Always use the spark plugs recommended 
for your snowmobile. Refer to the specifications section beginning on 
the page 116.

89

MAINTENANCE

Spark Plugs

Spark Plug Inspection

Spark plug condition is indicative of engine operation. The spark plug 
firing end condition should be read after the engine has been warmed up 
and the vehicle has been driven at higher speeds. Immediately check the 
spark plug for correct color.

CAUTION! A hot exhaust system and engine can cause burns. Wear 
protective gloves when removing a spark plug for inspection.

1. Remove the left side panel.

2. Remove the spark plug cap.

3. Using the special wrench provided in the tool pouch, rotate the 

spark plug counter-clockwise to remove.

4. Reverse the procedure for spark plug installation. Torque to specifi-

cation.

5. Reinstall the spark plug cap.

Spark Plug Condition

Normal Plug

The normal insulator tip is gray, tan or light brown. There will be few 
combustion deposits. The electrodes are not burned or eroded. This indi-
cates 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 nose. Generally, the 
electrodes are not worn. General causes of fouling are excessive oil or 
use of non-recommended injection oil.