Snowmobile Polaris 600 RUSH (2010 year). Instruction - part 32

 

  Index      Snowmobiles / ATV     Snowmobile Polaris 600 RUSH - instruction 2010 year

 

Search            

 

 

 

 

 

 

 

 

 

Content   ..  30  31  32  33   ..

 

 

Snowmobile Polaris 600 RUSH (2010 year). Instruction - part 32

 

 

4.24

Cleanfire Fuel Injection

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

© 2011 Polaris Sales Inc.

Fuel Rail/Injector Removal and Installation

Removal/Installation Process

NOTE:  Do not touch fuel injector inlet/outlet. Leave 
protective caps in place while handling.

1.

Open the door panels and remove the hood 
assembly.

2.

Relieve fuel system pressure.

3.

Disconnect the fuel supply and return hoses from the 
fuel pump.

4.

Remove the ECU, ECU bracket, and oil tank from the 
clutch cover assembly.

5.

Remove the air box intake tube and top to gain access 
to the fuel rail.

6.

Disconnect the fuel injector assembly wiring harness 
connector.

7.

Remove the two screws that mount the fuel rail to the 
cylinder.

8.

Carefully pull the rail away from the engine and 
injectors. Remove the injectors from the cylinder.

NOTE: Always use new o-rings/isolators after fuel 
injectors have been removed.

9.

Using a pick, remove the two fuel injector isolators or 
bushings from the injector ports in the cylinder. 
Discard the isolators/bushings.

10. Remove the fuel injector o-rings from fuel injectors. 

Discard the fuel injector o-rings.

11. To reinstall the fuel rail assembly, lightly coat two new 

fuel injector isolators with two-stroke engine oil. Install 
the new isolators or bushings into the cylinder injector 
ports.

12. Install four new oil-coated fuel injector o-rings.

13. Install both fuel injectors into the cylinder. Carefully 

install the fuel rail assembly.

14. Tighten fuel rail screws evenly. Once both screws are 

seated, torque to specification.

15. Reconnect the fuel injector harness wiring connector.

16. Reinstall the air box components.

17. Install the oil tank, ECU bracket, and ECU.

18. Reconnect the fuel supply and return fuel hoses on 

the fuel pump.

FUEL RAIL ASSEMBLY

FUEL INJECTOR ASM.

2011-ISOLATOR O-RING

A

A

FUEL RETURN

FUEL SUPPLY

2012-GREEN BUSHING

T 

A: 9 ft-lb (12 Nm)

4.25

Cleanfire Fuel Injection

4

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

© 2011 Polaris Sales Inc.

FUEL TANK/PUMP SERVICE

2010 Fuel Tank/Pump Assembly

SERVICE PARTS:

• Fuel Pump Assembly - 2520951

• Pickup/Sock Assembly (w/clamps and cable ties) - 

2204376

• PFA Gasket - 5413063

FUEL TANK

A

PFA GASKET

PFA NUT

CAP

VENT/VAC HOSE

SEAT MOUNT BRACKET

FUEL TANK BRACKET

PUMP ASSEMBLY

C

D

D

D

B

T 

A: 10 ft-lb (14 Nm)

B: 6 ft-lb (8 Nm)

C: 28 ft-lb (38 Nm)

D: 7 ft-lb (10 Nm)

CAUTION

ALWAYS REPLACE PFA GASKET WITH NEW 

GASKET AFTER REMOVING FUEL PUMP.

4.26

Cleanfire Fuel Injection

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

© 2011 Polaris Sales Inc.

2011-2012 RUSH/Switchback Fuel Tank/
Pump Assembly

SERVICE PARTS:

• Fuel Pump Assembly - (600 Rush) 2520951

(800 Rush) 2521107

• Pickup/Sock Assembly (w/clamps and cable ties) - 

2204376

• PFA Gasket - 5413063

FUEL TANK

A

PFA GASKET

PFA NUT

CAP

VENT/VAC HOSE

SEAT MOUNT BRACKET

FUEL TANK BRACKET

PUMP ASSEMBLY

C

D

D

D

B

WASHER

T 

A: 10 ft-lb (14 Nm)

B: 6 ft-lb (8 Nm)

C: 28 ft-lb (38 Nm)

D: 7 ft-lb (10 Nm)

CAUTION

ALWAYS REPLACE PFA GASKET WITH NEW 

GASKET AFTER REMOVING FUEL PUMP.

4.27

Cleanfire Fuel Injection

4

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

© 2011 Polaris Sales Inc.

2011-2012 Switchback Assault/RMK Fuel 
Tank/Pump Assembly

SERVICE PARTS:

• Fuel Pump Assembly (w/gasket) - 2521142

• Pickup Assembly (w/clamps-gasket) - 2520873

• PFA Gasket - 5413063

FUEL TANK

A

PFA GASKET

PFA NUT

CAP

VENT/VAC HOSE

SEAT MOUNT BRACKET

PUMP ASSEMBLY

C

D

PICKUP ASSEMBLY

T 

A: 10 ft-lb (14 Nm)

B: 6 ft-lb (8 Nm)

C: 28 ft-lb (38 Nm)

D: 7 ft-lb (10 Nm)

CAUTION

ALWAYS REPLACE PFA GASKET WITH NEW 

GASKET AFTER REMOVING FUEL PUMP.

 

 

 

 

 

 

 

Content   ..  30  31  32  33   ..