Snowmobile Polaris 600 RUSH (2010 year). Instruction - part 42

5.10

Final Drive/Brake System

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

© 2011 Polaris Sales Inc.

Mounting Assembly View

NOTE: 2012 Pro-Ride models feature a bonded 
chaincase.

Non-Bonded Chaincase Removal/

Installation

1.

Follow the procedures for chaincase disassembly.

2.

Follow the procedures for removing the track and 
driveshaft.

3.

Remove the fasteners securing the chaincase to the 
tunnel, front cooler/closeoff panel, and side support.

4.

Inspect the seals for excessive wear or damage. 
Replace as required.

5.

Verify bearings roll smoothly. Replace if they do not 
or if excessive play is evident. Use an arbor press to 
remove and install bearings.

6.

To install the chaincase, loosely install all of the 
fasteners using new lock nuts where applicable.

7.

Verify fastener (1) is installed in the lower chaincase 
mounting hole has shown in the illustration.

8.

Torque fasteners to specifications.

9.

Follow the procedures for reinstalling the driveshaft 
and track.

10. Follow the procedures for chaincase assembly.

1

2

3

3

3

3

A

B

C

C

C

C

Align with bulkhead cooler.

4

Stud Plate-RMK Models Only
Tunnel Reinforcement Plate-Switchback Only

REFERENCE

 #

DESCRIPTION

1

Screw-M8x1.25x35.8 

2

Screw - M8x1.25x30.8

3

Carriage Bolts-M6x1.0x20

4

Stud Plate (RMK models only)

Reinforcement Plate (Switchback only-not 

shown.)

CAUTION

Do not re-use lock Nuts. Always replace with new parts 

after removal.

= T 

A: 26 ft-lb (35 Nm) DO NOT OVER-TORQUE



B: 26 ft-lb (35 Nm)



C: 14 ft-lb (19 Nm)

5.11

Final Drive/Brake System

5

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

© 2011 Polaris Sales Inc.

Bonded Chaincase Removal/Installation

1.

Follow the procedures for chaincase disassembly.

2.

Follow the procedures for removing the track, rear 
suspension, and driveshaft.

3.

Remove the fasteners securing the chaincase to the 
tunnel, front cooler/closeoff panel, and side support.

4.

While wearing protective gloves and clothing, use a 
propane torch to evenly heat the backside and 
fastener points of the chaincase/tunnel.

5.

While applying heat, carefully and slowly pull the 
chaincase assembly away from the tunnel. Use 
extreme care as to not distort the tunnel.

6.

Allow the chaincase to properly cool. Once cooled, 
inspect the seals for excessive wear or damage. 
Replace as required.

7.

Verify bearings roll smoothly. Replace if they do not 
or if excessive play is evident. Use an arbor press to 
remove and install bearings.

8.

Thoroughly clean the chaincase-to-tunnel mating 
surfaces. All residual bonding adhesive MUST be 
removed. Use a putty knife and wire brush to remove 
material.

9.

After removing residual adhesive, wash parts in 
solution of warm, soapy water and allow to air dry.

10. Begin chaincase installation by verifying all fasteners 

are accounted for and staged for installation.

11. Verify the chaincase and tunnel mating surfaces are 

clean and free of dirt, and oil residue.

12. Reference Adhesive Applicator Kit and Adhesive 

Application sections in Chapter 9. See “Bonded 
Component Service” on page 9.21.

NOTE: The Bonded Component Service section in 
Chapter 9 outlines the adhesive, applicator tools, and 
the adhesive application procedure required to 
properly install bonded components.

13. After the adhesive has been applied to the backside 

of the chaincase, quickly install all of the fasteners.

14. Verify fastener (1) is installed in the lower chaincase 

mounting hole has shown in the illustration. See 
“Mounting Assembly View” on page 5.10.

15. Torque fasteners to specifications.

16. Follow the procedures for reinstalling the driveshaft 

and track.

17. Follow the procedures for chaincase assembly.

CAUTION

Keep flame away from flammable materials. Use 

propane torch in well-ventilated area.

Only apply heat to area that requires adhesive bond 

separation. Do not apply heat to areas of adhesive 

where bond line separation is not needed. Doing so will 
require removing the part, removing adhesive, and then 

re-applying new adhesive.

= T 

A: 26 ft-lb (35 Nm) DO NOT OVER-TORQUE



B: 26 ft-lb (35 Nm)



C: 14 ft-lb (19 Nm)

ADHESIVE

LINE

ADHESIVE

LINE

5.12

Final Drive/Brake System

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

© 2011 Polaris Sales Inc.

DRIVESHAFT/JACKSHAFT

Specifications/Torque Guide

Assembly View

NOTE: The PTO ends of the jackshaft/driveshaft 
feature sealed bearings. No grease required.

COMPONENT

TORQUE

Jackshaft Flange Nuts

18 ft-lb (25 Nm)

Speedometer Flange Nuts

18 ft-lb (25 Nm)

Driveshaft Flange Nuts

18 ft-lb (25 Nm)

Driven Clutch Fastener

18 ft-lb 25 Nm)

Speed Sensor Screw

18 ft-lb 25 Nm)

1

2

3

4

5

6

NUT PLATE-2011-CURRENT

REFERENCE

 #

DESCRIPTION

1

Flangette

2

Jackshaft

3

Driveshaft

4

Gasket

5

Speedometer Housing

6

Nut Pals

CAUTION

Do not re-use lock Nuts. Always replace with new parts 

after removal.

REFERENCE

 #

DESCRIPTION

5.13

Final Drive/Brake System

5

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

© 2011 Polaris Sales Inc.

Jackshaft Removal

1.

Follow the procedures for chaincase disassembly.

2.

Remove the driven clutch assembly.

3.

Remove the oil tank/clutch cover assembly. Remove 
the airbox.

4.

Remove the jackshaft flangette screws and nuts or nut 
plate. Discard the lock Nuts.

5.

Carefully pull the jackshaft from the clutch-side of the 
vehicle out of the chaincase. Remove jackshaft from 
vehicle.

Jackshaft Installation

1.

Carefully insert the jackshaft through the bulkhead 
and into the chaincase.

2.

Using new lock Nuts, install the jackshaft flangette. 
Torque nuts to specification.

3.

Reinstall the airbox assembly and driven clutch. 
torque driven clutch fastener to specification.

4.

Follow the procedures for chaincase assembly.

NOTE: The jackshaft features a sealed bearing. No 
grease is required.

Driveshaft Removal

1.

Follow the procedures for chaincase disassembly.

2.

Remove the driven clutch assembly.

3.

Remove the track/rear suspension from the vehicle.

4.

Remove the nuts securing both the speedometer 
housing to the chassis and the nuts securing the 
driveshaft to the speedometer housing. Discard the 
lock Nuts.

5.

Carefully pull the driveshaft from the clutch-side of the 
vehicle out of the chaincase. When the driveshaft 
clears the chaincase, drop it down through the tunnel 
and then remove the driveshaft from the vehicle.

6.

Inspect the drive sprockets for damage and excessive 
wear. Complete driveshaft replacement is required if 
sprockets or bearing are damaged.

7.

Inspect the gasket. Replace if worn or damaged.

Driveshaft Installation

1.

From underneath the tunnel, insert the flangette-side 
of the driveshaft through the bulkhead.

2.

Once aligned with the chaincase, carefully insert the 
spline-end into the lower chaincase hole.

3.

Verify the gasket is not damaged or torn.

4.

Using new lock nuts, loosely install both the driveshaft 
and speedometer flangette.

5.

Torque the speedometer housing and driveshaft nuts 
to specifications.

6.

Install the driven clutch assembly. Torque driven 
clutch fastener to specification.

7.

Reinstall the track/rear suspension.

8.

Follow the procedures for chaincase assembly.

NOTE:  The driveshaft features a sealed bearing. No 
grease is required.



The speedometer sensor pickup gear is not 
serviceable.

= T 

Jackshaft Flange Nuts: 18 ft-lb (25 Nm)

= T 

Driven Clutch Fastener: 18 ft-lb (25 Nm)

= T 

Speedometer Housing/Driveshaft Nuts:



18 ft-lb (25 Nm)

= T 

Driven Clutch Fastener: 18 ft-lb (25 Nm)