Snowmobile Polaris 600 RUSH (2010 year). Instruction - part 17

 

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Snowmobile Polaris 600 RUSH (2010 year). Instruction - part 17

 

 

3.18

Engine/Cooling/Exhaust

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

© 2011 Polaris Sales Inc.

2011 800 Engine Mounting

Assembly Notes:

• ENGINE MOUNT BOLTS-Always clean engine 

mount strap threads with compressed air or 

M10x1.5 tap before installing screw(s). Apply 
Loctite® 243™ when using original bolt.

• To prevent the engine mount bolts 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

ENGINE MOUNTS

MOUNT BRACKET

MOUNT W/CLINCH NUT

MOUNT W/CLINCH NUT (PTO-SMALL)

RADIAL INSERT (SMALL)

MOUNT

MOUNT

RADIAL INSERT (LARGE)

E

E

E

C

C

B

B

A

A

A

E(NO Loctite®)

B

C

C

B

RADIAL INSERT (LARGE)

RADIAL INSERT (LARGE)

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.

3.19

Engine/Cooling/Exhaust

3

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

© 2011 Polaris Sales Inc.

2012 600/800 Engine Mounting

Assembly Notes:

• ENGINE MOUNT BOLTS-Always clean engine 

mount strap threads with compressed air or 

M10x1.5 tap before installing screw(s). Apply 
Loctite® 243™ when using original bolt.

• To prevent the engine mount bolts 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

D

E

ENGINE ASSEMBLY

BRACKET

TORQUE LINK INNER

TORQUE LINK

TORQUE LINK OUTER
BRACKET

TORQUE LINK MOUNT

ENGINE MOUNTS

MOUNT BRACKET

MOUNT W/CLINCH NUT

MOUNT W/CLINCH NUT (PTO-SMALL)

RADIAL INSERT (SMALL)

MOUNT

MOUNT

RADIAL INSERT (LARGE)

E

E

E

C

C

B

B

A

A

A

E(NO Loctite®)

B

C

C

B

RADIAL INSERT (LARGE)

RADIAL INSERT (LARGE)

T 

A = 40 ft-lb (54 Nm) Apply Loctite® 243™ 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.

3.20

Engine/Cooling/Exhaust

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

© 2011 Polaris Sales Inc.

Engine Mount Bolt Service Replacement Kit

A service kit has been developed to replace the original 
engine mount fastener bolts used on 2010-2011 600/800 
Pro-Ride vehicles to the 2012 fastener specification.

The engine mount bolt replacement kit includes the 
following parts:

• PN 7519334 - 4QTY. - Bolts-M10X1.5X50 12.9

• PN 3022426 - 2QTY. - Radial Inserts (Small)

(600/800s - Front PTO / 2010-2011 600s Rear 
PTO ONLY)

• PN 3022409 - 3 QTY. - Radial Inserts (Large)

(600/800s - MAG Front and Rear / 2011 800 Rear 
PTO)

The engine mount bolt replacement kit will replace all four 
engine mount bolts along with their associated radial 
inserts. The original bolts (part numbers: 7519009 and 
7519282) will sub to the 2204633 kit part number.

Bolt identification can be quickly made by measuring the 
head diameter of the bolt. Bolts used on 2010-2011 Pro-
Ride vehicles have 14mm head diameters, while the 
replacement bolts have 16mm heads and feature a 
knurled edge.

A selection of radial inserts is included with the kit. All 
2010-2011Pro-Ride MAG-side engine mounts use large 
radial inserts.

On the PTO side, all 2010-2011 600 Pro-Ride models use 
small radial inserts in both the front and back locations.

All 2011 800 Pro-ride models feature a small PTO-front 
and large PTO-rear radial insert.

IMPORTANT: 

It is recommended that all engine 

mount bolts be replaced if removed. If bolt 
replacement is not possible, the bolt(s) must be 
replaced after TWO installation cycles. It is 
recommended that the technician marks the bulkhead 
to count the number of installations at each bolt(s) 
location.

Engine Mount Screw Installation

1.

Determine which bolt(s) is going to be installed.

NOTE: Polaris recommends installing the Engine 
Mount Bolt Replacement Kit (PN 2204633) if original 
2010-2011 bolts are installed.

2.

Clean the engine mount strap threads with 
compressed air and/or M10x1.5 tap.

3.

Apply Loctite® 243™ or Loctite® 242™ w/Primer N™ 
to 5-6 bolt threads.

4.

Reference torque specifications and install bolt(s).

5.

Apply final torque to bolt(s) using the following order:

Loosen already-installed bolts 1 full turn to accommodate 
torque pattern if required.

• PTO-REAR

• PTO-FRONT

• MAG-REAR

• MAG-FRONT

Engine Mount Bolt Replacement Kit

PN 2204633

T 

2010 - 14mm Head Diameter - DK.Green Color

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


2011 - 14mm Head Diameter - Silver/Gray Color

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


2012/Replacement Kit - 16mm Head Diameter

Silver/Gray Color

SILVER/GRY-M10x1.50 (12.9) = 40 ft-lb (54 Nm)

3.21

Engine/Cooling/Exhaust

3

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

© 2011 Polaris Sales Inc.

RECOIL ASSEMBLY

Rope Removal and Installation

1.

Remove recoil housing from the engine. Un-tie knot in 
the recoil rope and allow the reel to slowly unwind.

2.

Remove the screw, washer, friction plate, ratchet 
guide, friction spring, ratchet and return spring from 
the reel.

3.

Lift the reel straight out of the housing making sure the 
spring is no longer connected to the backside of the 
reel.

NOTE: If the recoil spring tension is removed, the 
spring should stay inside the housing.
4.

Inspect all components for signs of abnormal wear. 
Replace components as required. If replacing the 
rope, tie a small square knot at one end. Push the knot 
firmly into the pocket on the reel.

5.

If the reel recoil spring was removed during 
disassembly, install the spring by spiraling the spring 
counterclockwise toward the center of the housing.

6.

Lubricate the center shaft and spring with Premium 

grease.

7.

Wind the rope counterclockwise around the pulley as 
viewed from the ratchet-side of the reel.

8.

Pass the end of the rope through the hole in the 
housing. If the rope guide was removed from the 
housing, reinstall it before attaching the rope handle.

9.

Slide the reel down the center shaft and into the 
housing making sure the recoil spring re-engages the 
reel tab.

10. Install the return spring and ratchet into the reel face. 

The return spring leg fits in the notch on the ratchet 
and holds the ratchet in (retracted).

11. Install friction spring with one leg inserted in the 

bottom hole on the ratchet.

12. Apply Loctite® 242™ and install screw and washer 

and torque to specification.

13. Pull rope out to its full extension and align pulley notch 

with rope hole in housing.

14. Using a needle nose pliers or hooked wire, pull a loop 

of rope through the notch in the reel.

15. Prevent the rope from being retracted by tieing a knot 

in the rope on the outside of the housing at the rope 
guide hole.

16. Wind the recoil pulley counterclockwise until the 

spring begins to bind. Unwind the pulley clockwise two 
revolutions.

17. Pull on the rope to disengage it from the notch in the 

pulley. Un-tie the knot in the rope and allow it to retract 
into the housing.

18. Pull on the handle to verify proper operation.

FRICTION PLATE

FRICTION SPRING

RATCHET

RETURN SPRING

ROPE

RECOIL HUB

RECOIL SPRING

TAB (ENGAGES INSIDE HOUSING)

TAB (ENGAGES INSIDE PULLEY)

ROPE GUIDE (HOLE)

BUSHING

REEL

RATCHET GUIDE

HANDLE

SCREWS

SCREW\

SCREWS

COVER

T 

Cover/Hub Screws: 9 ft-lb (12Nm)

Friction Plate Screw:

1204173 Recoil Assembly: 9 ft-lb (12 Nm)

1204331 Recoil Assembly: 14 ft-lb (19 Nm)

CAUTION

Recoil spring under high tension. Wear eye protection.

 

 

 

 

 

 

 

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