Snowmobile Polaris 600 RUSH (2010 year). Instruction - part 18

 

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Snowmobile Polaris 600 RUSH (2010 year). Instruction - part 18

 

 

3.22

Engine/Cooling/Exhaust

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

© 2011 Polaris Sales Inc.

ENGINE COMPONENT ASSEMBLIES

600 Cylinder Head/Cylinders/Pistons

A

B

C

E

D

F

BLEED SCREW

GASKET

THERMOSTAT

THERMOSTAT COVER

HEAD COVER

TEMP. SENSOR

CYLINDER HEAD

O-RINGS

KNOCK SENSOR

O-RINGS

BASE GASKETS

CYLINDERS

PISTON RINGS

PISTON PIN

C-CLIP

PISTON

BEARING

T 

A: 70 in-lb (8 Nm)

B: 9 ft-lb (12 Nm) - Apply Loctite® 242™

C: 25 ft-lb (34 Nm) - Apply Loctite® 242™

D: 18 ft-lb (24 Nm) - Apply Pipe Sealant

E: 168 in-lb (19 Nm) - Clean and Dry

(DO NOT UNDER/OVER TORQUE SCREW.)

F: 37 ft-lb (50 Nm)

Piston Matrix

Engine Model

Piston PN

Piston ID

S4202-6044-OP6N

S4215-6044-OO6N

S4357-6044-OL6N

2204152

3222

S4316-6044-OL6G
S4452-6044-OL6G

2204659

3226

Piston Matrix

Engine Model

Piston PN

Piston ID

3.23

Engine/Cooling/Exhaust

3

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

© 2011 Polaris Sales Inc.

Disassembly / Assembly Process

1.

Remove the coolant from the engine using a siphon, 
wet/dry vac, or drain pan.

2.

Remove the oil tank/clutch cover, air box assembly, 
and exhaust pipe from the engine compartment.

3.

Remove the high tension wires and spark plugs from 
the cylinder head.

4.

Remove the thermostat housing outlet cooling hose 
from the housing.

5.

Loosen all, then remove all head cover fasteners. 
Clean the fastener threads to remove any thread 
locking residue.

6.

Discard the head cover and cylinder head o-rings. 
Always use new o-rings during assembly.

7.

Inspect the cylinder head / combustion domes for any 
damage. Measure cylinder head flatness. Replace 
cylinder head if required.

8.

If only the cylinder(s) are going to be removed, 
remove the fuel rail from the upper fuel injectors. 

9.

Loosen all, then remove the cylinder base nuts.

10. Carefully pull each cylinder upwards taking care not 

to drop the piston and rod abruptly against the 
crankcase.

11. Remove the cylinder base gaskets. Use a gasket 

scraper to clean the gasket residue from the 
crankcase and cylinder bases.

12. Inspect the cylinder walls. Nicasil cylinders can only 

be lightly honed. Damage that cannot be removed 
with a light hone requires cylinder replacement or re-
chroming.

13. The assembly process is the reverse of disassembly.

14. Always use new gaskets and o-rings during 

assembly. Liberally coat the inside of each cylinder 
and the outside of each piston with Polaris two-stroke 
engine oil.

15. Always refresh the cylinder crosshatch pattern using 

a 320 grit stone. See “Cylinder Honing” on page 3.14. 

16. When installing a piston into a cylinder, verify each 

piston ring opening is located at each piston ring 
locating pin. Squeeze the top ring, then carefully slide 
the cylinder over the compressed ring. Do the same 
with the bottom ring.

17. Follow the torque specifications and torque 

sequences located at beginning of chapter when 
tightening fasteners.

3.24

Engine/Cooling/Exhaust

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

© 2011 Polaris Sales Inc.

600/800 Recoil/Stator Assembly

RECOIL HOUSING

HUB

FLYWHEEL

FLYWHEEL NUT

A

B

C

D

STATOR

TRIGGER COILS

A

T 

A: 9 ft-lb (12 Nm)

B: 5 ft-lb (7 Nm) (Trigger coil fasteners)

C: 90 ft-lb (122 Nm) - Apply Loctite® 242™ (Do not 
use an impact wrench to remove or install flywheel 
nut.)

D: 12 ft-lb (16 Nm) - Apply Loctite® 242™

3.25

Engine/Cooling/Exhaust

3

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

© 2011 Polaris Sales Inc.

Disassembly / Assembly Process

1.

Remove the exhaust pipe and silencer.

2.

If the recoil assembly does not require attention, the 
recoil rope can remain attached to the handle. If recoil 
component work is desired, reference the Recoil 
Assembly section. 

3.

Remove the two mag-side engine mounting bolts. 
Carefully lift the mag-side of the engine to access the 
housing cover.

4.

Remove the recoil/magneto housing cover. The recoil 
assembly is located inside the housing.

5.

Remove the recoil hub from the flywheel. Secure the 
flywheel with a strap wrench, PN PU-45419. Remove 
the flywheel nut and washer.

6.

Using the flywheel puller tool, PN 2871043, insert the 
puller’s three screws into the flywheel.

NOTE: Do not thread the puller screws into the 
magneto/stator located behind the flywheel.

7.

Turn the puller center bolt in until the flywheel “pops” 
off of the crankshaft.

8.

Mark the location of the magneto/stator plate in 
several places using a scribe.

9.

Remove the two plastic rivets that prevent the trigger 
coil wires from contacting the flywheel.

10. Remove the magneto/stator from the crankcase.

11. During assembly, route the trigger coil wires in their 

designated channels. Install the two plastic rivets into 
the housing to prevent the wires from accidently 
coming into contact with the flywheel.

12. Assembly is reverse of disassembly. Reference the 

fastener torque specifications at the beginning of the 
chapter.

13. Do not use an impact wrench to install the flywheel 

nut.

14. Align the mag-side engine mount with the two chassis 

mounts. Install the engine mount screws and torque 
to specification.

15. Reinstall the exhaust silencer and pipe.

 

 

 

 

 

 

 

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