Snowmobile Polaris 600 RUSH (2010 year). Instruction - part 16

 

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Snowmobile Polaris 600 RUSH (2010 year). Instruction - part 16

 

 

3.14

Engine/Cooling/Exhaust

9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

© 2011 Polaris Sales Inc.

Cylinder Honing

The cylinder bore must be de-glazed whenever new 
piston rings are installed. A light honing with fine stones 
removes only a very small amount of material. A proper 
crosshatch pattern is important to provide a surface that 
will hold oil, and allow the rings to seat properly. If the 
crosshatch is too steep, oil retention will be reduced. A 
crosshatch angle which is too shallow will cause ring 
vibration, poor sealing, and overheating of the rings due 
to blow-by and reduced contact with the cylinder wall. 
Service life of the pistons and rings will be greatly 
reduced.

NOTE:  A Nicasil cylinder can be lightly honed with a 
320 grit stone hone but can not be oversized.

Honing Tools

The following tools are recommended:

• Ammco 3950 Hone Kit - SPX PN 2870303 / 

commercially available

• Ammco 3956 Honing Stones (320 grit / Oversize)

• Honing Oil - Commercially Available

Honing Procedure

1.

Wash the cylinder with cleaning solvent.

2.

Clamp the cylinder in a soft jawed vise by the cylinder 
studs.

3.

Place hone in cylinder and tighten stone adjusting 
knob until stone contacts the cylinder walls (DO NOT 
OVERTIGHTEN).

4.

Apply honing oil to the stones and cylinder walls. Wet 
honing removes more material faster and leaves a 
more distinct pattern in the bore.

5.

Using a 1/2" (13 mm) drill motor rotating at a speed of 
300-500 RPM, run the hone in and out of the cylinder 
rapidly until cutting tension decreases. Remember to 
keep the hone drive shaft centered to prevent edge 
loading and always bring the stone approximately 1/
2" (1.2 cm) beyond the bore at the end of each stroke.

6.

Release the hone at regular intervals to inspect bore 
size and finish.

Cleaning The Cylinder After Honing

It is very important that the cylinder be thoroughly cleaned 
after honing to remove all grit material. Wash the cylinder 
in a solvent, then in hot soapy water. Pay close attention 
to areas where the cylinder sleeve meets the aluminum 
casting (transfer port area). Use electrical contact cleaner 
if necessary to clean these areas. Rinse thoroughly, dry 
with compressed air, and oil the bore immediately with 
Polaris Premium 2 Cycle Lubricant.

NOTE: Always check piston to cylinder clearance 
and piston ring installed gap after honing is complete.

EXAMPLE OF A CROSS HATCH PATTERN

3.15

Engine/Cooling/Exhaust

3

9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

© 2011 Polaris Sales Inc.

Crankshaft Truing

Lubricate the bearings and clamp the crankshaft securely 
in the holding fixture. If truing the crankshaft requires 
striking with a hammer, always be sure to re-check 
previously straightened areas to verify truing. Refer to the 

illustrations below. Use Crankshaft alignment kit PN 
2870569.

NOTE: The rod pin position in relation to the dial 
indicator tells you what action is required to 
straighten the shaft.

Truing Examples

To correct a situation like this. Strike the shaft at 
point A with a brass hammer.

To correct a situation like the one shown in this. 
Squeeze the crankshaft at point A. You will use the 
tool from the alignment kit PN 2870569.

If the crank rod pin location is 180° from the dial 
indicator (opposite of above), it will be necessary to 
spread the crankshaft at the A position as shown in 
illustration 3. When rebuilding and straightening a 
crankshaft, straightness is of utmost importance. 
Runout must be as close to zero as possible.

3.16

Engine/Cooling/Exhaust

9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

© 2011 Polaris Sales Inc.

ENGINE MOUNTING SYSTEMS

2010 600 Engine Mounting

Assembly Notes:

• ENGINE MOUNT BOLTS-Note two torque values 

for screws. Always clean engine mount threads 
with compressed air or M10x1.5 tap before 
installing screw(s). Apply Loctite® 242™ when 
using original screw.

• To prevent the engine mount screws from catching 

on the radial inserts, spray the inserts with rubber 
lubricant or isopropyl before installing engine 
mount fasteners.

• Replace lock nuts with new parts when removed.

• Torque link length (center-to-center) = 3.33" 

(84.63mm)

ENGINE ASSEMBLY

ENGINE MOUNTS

C

A

A

A

A

RADIAL INSERT (SMALL)

RADIAL INSERT (SMALL)

MOUNT W/CLINCH NUT

MOUNT W/CLINCH NUT

MOUNT

MOUNT

RADIAL INSERT (LARGE)

MOUNT BRACKET

MOUNT BRACKET

TORQUE LINK MOUNT

TORQUE LINK

TORQUE LINK OUTER

BRACKET

TORQUE LINK INNER

BRACKET

B

B

B

B

C

C

C

C

B

A

C

D

E

F

F

F

NOTE: SEE ENGINE MOUNT BOLT SERVICE REPLACEMENT KIT

T 

A =

DK. GREEN-M10x1.5x45 (8.8) = 30 ft-lb (41 Nm)

SILVER/GRY-M10x1.5x50 (12.9) = 35 ft-lb (48 Nm)

B = 9 ft-lb (12 Nm)

C = 26 ft-lb (35 Nm)

D = 18 ft-lb (24 Nm)

E = 12.5 ft-lb (17 Nm)

F = 30 ft-lb (41 Nm) Apply Loctite® 242™ to threads.

3.17

Engine/Cooling/Exhaust

3

9923311 - 2010-2012 PRO-RIDE RUSH/Switchback/RMK Service Manual

© 2011 Polaris Sales Inc.

2011 600 Engine Mounting

Assembly Notes:

• ENGINE MOUNT SCREWS-Always clean engine 

mount threads with compressed air or M10x1.5 tap 

before installing screw(s). Apply Loctite® 242™ 
when using original screw.

• To prevent the engine mount screws from catching 

on the radial inserts, spray the inserts with rubber 
lubricant or isopropyl before installing engine 
mount fasteners.

• Replace lock nuts with new parts when removed.

A

MOUNT BRACKET

C

C

D

E

ENGINE ASSEMBLY

BRACKET

TORQUE LINK INNER

TORQUE LINK

TORQUE LINK OUTER
BRACKET

TORQUE LINK MOUNT

MOUNT BRACKET

ENGINE MOUNTS

MOUNT W/CLINCH NUT

RADIAL INSERT(SMALL)

MOUNT W/CLINCH NUT

RADIAL INSERT(SMALL)

MOUNT

MOUNT

RADIAL INSERT (LARGE)

E

E

E

C

C

B

B

B

A

A

A

E(NO Loctite®)

B

C

C

B

NOTE: SEE ENGINE MOUNT BOLT SERVICE REPLACEMENT KIT

T 

A = 35 ft-lb (48 Nm) Apply Loctite® 242™ to 
threads.

B = 9 ft-lb (12 Nm)

C = 26 ft-lb (35 Nm)

D = 18 ft-lb (24 Nm)

E = 30 ft-lb (41 Nm) Apply Loctite® 242™ to threads.

 

 

 

 

 

 

 

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