Snowmobile Polaris 600 RUSH (2010 year). Instruction - part 19

 

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Snowmobile Polaris 600 RUSH (2010 year). Instruction - part 19

 

 

3.26

Engine/Cooling/Exhaust

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

© 2011 Polaris Sales Inc.

600 Crankcase/Crankshaft Assembly

GEAR CLAMPS

INTAKE BOOT

REED STUFFERS

REED BLOCKS

CYLINDER STUDS

NEEDLE BEARINGS

PTO SEAL

MAG SEAL

MAG BEARING

PTO BEARINGS

FLYWHEEL KEY

CRANKSHAFT

OIL INJECTION CHECK VALVE QTY. 5

ALIGNMENT DOWELS

A

B

C

TRIGGER COIL WIRE RETAINER

STATOR WIRE HARNESS RETAINER

TRIGGER COIL WIRE RETAINER

DO NOT FILL MAG 

BEARING OIL 

GALLERY WITH CASE 

SEALANT

In. / mm. 

Long Stud Height (Exhaust side): 4.13" (105mm)

Small Stud Height (Intake side): 2.16" (55mm)

T 

A: 9 ft-lb (12 Nm)

B: 22 ft-lb (30 Nm)

C: 10 ft-lb (13 Nm) - Apply Pipe Sealant

3.27

Engine/Cooling/Exhaust

3

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

© 2011 Polaris Sales Inc.

Disassembly / Assembly Process

1.

Remove the engine from the engine compartment. 

2.

Follow the process for removing the cylinder head, 
cylinders, pistons, flywheel / recoil housing, and the 
water / oil pump.

3.

Remove the intake boots, reed stuffers, and reed 
assemblies from the intake tracks. Discard any seals 
or gaskets.

NOTE:  The crankcase ring land damage shown in the 
corresponding photo is caused by improper 
crankcase separation or crankshaft removal.

4.

Remove all crankcase fasteners except ones marked 
5-6-7-8 indicated below. Loosen these 4 bolts to 
reveal about a 1/6"-1/8" bolt gap.

5.

Once loosened, carefully and lightly tap on the bolts 
to separate the crankcase halves.

6.

Discard the PTO and MAG crankshaft seals.

7.

Remove the crankshaft by pulling it straight up and 
out. Inspect as required.

8.

Thoroughly clean the two crankcase mating surfaces 
with carburetor cleaner and a gasket remover. Flush 
out the crankcase galleries.

9.

Reinstall the crankshaft back into the lower crankcase 
using two new crankcase seals. Verify the two 
crankcase dowels are installed in the lower 
crankcase.

10. Apply a thin bead of Three Bond 1217H to the lower 

crankcase mating surface. Install the upper 
crankcase.

NOTE:  Do not over-apply sealant in oil injector area. 
Doing so may block the oil passage.

11. Loosely install the crankcase fasteners, then torque to 

the specifications at the beginning of the chapter. Use 
the correct torque sequence when tightening the 
screws.

12. Liberally coat the crankshaft bearings and 

components with Polaris two-stroke engine oil.

DO NOT FILL MAG 

BEARING OIL 

GALLERY WITH 

CASE SEALANT

DOWELS

3.28

Engine/Cooling/Exhaust

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

© 2011 Polaris Sales Inc.

800 DC-CFI-2 Cylinder Head/Cylinder/

Pistons

BLEED SCREW

THERMOSTAT COVER

THERMOSTAT

SPARK PLUGS

GASKET

HEAD COVER

TEMP. SENSOR

THROTTLE BODY HOSE

PLUG*

BYPASS NOZZLE*

KNOCK SENSOR

PISTON

C-CLIP

PISTON RINGS

PISTON PIN

BASE GASKET

CYLINDER

CYLINDER HEAD

O-RINGS

* = SEE PLUG / BYPASS MATRIX

O-RINGS

A

B

D

E

F

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 OVER/UNDER TORQUE SCREW.)

F: 42 ft-lb (57 Nm)

3.29

Engine/Cooling/Exhaust

3

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

© 2011 Polaris Sales Inc.

Cylinder Head/Cylinder/Piston Notes

800 pistons feature two different rings thicknesses. The 
upper ring is 1.8mm thick, while the lower ring is 1.5mm 
thick.

Some 800 DC-CFI-2 engines feature a coolant bypass 
nozzle on the cylinder head. Reference table below. 

800 DC-CFI-2 Cylinder Head/Cylinder/

Pistons Disassembly/Assembly

1.

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

2.

Remove the air box, exhaust pipe and resonator 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.

Remove the fuel rail and fuel injectors from cylinder. 
See “Fuel Rail/Injector Removal and Installation” on 
page 4.24.

NOTE: Leave the exhaust Y-pipe attached to the 
cylinder assembly. Remove Y-pipe after removing 
cylinder from crankcase.

9.

Loosen all, then remove the cylinder bolts. Clean the 
bolt threads to remove any thread locking residue.

10. Carefully pull the cylinder upwards taking care not to 

drop the pistons and rods abruptly against the 
crankcase.

11. Remove the cylinder base gasket. Use a gasket 

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

12. Inspect the cylinder walls. Nicasil cylinders can only 

be lightly honed using a 320 grit stone. Damage that 
cannot be removed with a light hone requires cylinder 
replacement or re-chroming.

13. Inspect the crankcase and cylinder mating surfaces 

for warping.

14. The assembly process is the reverse of disassembly.

15. Always use new gaskets and o-rings during 

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

16. Always refresh the cylinder crosshatch pattern using 

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

17. 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.

18. Follow the torque specifications and torque 

sequences located at beginning of chapter when 
tightening fasteners.

Piston Matrix

Engine Model

Piston PN

Piston ID

S4139-8044-OO8G

S4229-8044-OO8G

S4092-8044-OO8G

S4360-8044-OL8G

S4361-8044-OL8G

S4359-8044-OL8G

2204322

3305 or 3335

Plug / Bypass Matrix

Engine Model

Cylinder Head 

Plug

Cylinder Head 

Bypass Nozzle

S4139-8044-OO8G

S4229-8044-OO8G

S4360-8044-OL8G

S4361-8044-OL8G

X

S4092-8044-OO8G

S4359-8044-OL8G

X

 

 

 

 

 

 

 

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