Snowmobile Polaris 600 RUSH (2010 year). Instruction - part 81

 

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Snowmobile Polaris 600 RUSH (2010 year). Instruction - part 81

 

 

10.20

Battery and Electrical Systems

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

© 2011 Polaris Sales Inc.

Starter Motor/Flex Drive Assembly

Starter Motor/Flex Drive Service

The starter motor, flex drive, and pinion gear can be 
serviced with the engine in the snowmobile.

1. Remove the exhaust pipe. If servicing the motor, 

remove the silencer.

2. When servicing the pinion gear, remove the y-pipe.

3. Using a ball-end allen wrench, remove the 3 screws 

attaching the pinion assembly to the engine.

4. To remove the starter motor, remove the gear clamp, 

and then the two-rear starter motor mount nuts.

5. During assembly, install the flex drive on to the pinion 

assembly. Install the three pinion assembly screws 
and torque to specification.

6. Loosely fit the gear clamp around the motor, and then 

install the flex drive on to the motor shaft.

7. Torque the rear nuts to specification.

8. Torque the gear clamp hand tight.

9. Reinstall the y-pipe. Torque fasteners to specification.

10. Reinstall the silencer and exhaust pipe.

FLEX DRIVE

END PLATE MOUNTING BRACKET

STARTER MOTOR

PINION/PINION BRACKET

WORM GEAR CLAMP

A

B

B

C

CAUTION

Disconnect battery before servicing starter motor 

components.

Always remove RED(+) battery cable first, and then 

BLACK(-) cable. Reverse order during battery 

installation.

T 

A = 22 ft-lb (30 Nm)

B = 7 ft-lb (10 Nm)

C = 8 ft-lb (11 Nm)

10.21

Battery and Electrical Systems

10

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

© 2011 Polaris Sales Inc.

Battery Box Assembly

BATTERY BOX

BATTERY

HEAT SHEILD

CIRCUIT BREAKER

SOLENOID

GROUND CABLE

POSITIVE CABLE (SOLENOID TO BATTERY)

CIRCUIT BREAKER LEAD

POSITIVE CABLE (SOLENOID TO STARTER MOTOR)

STRAP

A

A

B

B

A

A

A

A

CAUTION

Always disconnect RED(+) battery cable first, and then 

BLACK(-) cable. Reverse order during battery 

installation.

T 

A = 7 ft-lb (10 Nm)

B = 8 ft-lb (11 Nm)

10.22

Battery and Electrical Systems

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

© 2011 Polaris Sales Inc.

IGNITION TIMING

Timing Procedure

NOTE:  Before performing procedure, verify there are 
no current trouble codes and that all of the engine 
electrical connections are clean and tight.

1. Reference the timing specification chart and locate 

the piston BTDC measurement for 18°.

2. Install a dial indicator gauge into the MAG spark plug 

hole.

3. Place the MAG piston at 18° BTDC. Mark the flywheel.

NOTE: Each 10 degree mark is separated by lines 
every 2 degree. Acceptable timing variance is +/- 2 
degrees.

4. Connect timing light to the engine according to 

manufacturer's instructions.

5. Start and run the engine at idle speed until the engine 

temperature is 120°F (49°C). Verify the throttle lever 
is closed and the engine is at idle speed (1700 +/- 100 
RPM).

NOTE: 

The engine temperature must be 

approximately 120°F (49°C) to obtain accurate timing 
specification.

6. Point the timing light at the timing inspection hole.

7. With your head positioned so there is a straight line 

between your eye, the stationary pointer and the 
crankshaft center line, note the relative position 
between the marked flywheel line and the pointer. If 
the stationary pointer is aligned with the mark made 
in Step 3, or within the acceptable variance, ignition 
timing is correct.

NOTE: The stator plate, two-tooth, and five-tooth 
crankshaft position sensor locations are not 
adjustable.

8. If the pointer is outside the variance, either the 

flywheel key has sheared allowing the flywheel to 
move on the crankshaft, the crankshaft is out of index, 
a problem with the engine electrical harness exists, or 
one of the crankshaft position sensors has moved.

Flywheel

Rotation

10.23

Battery and Electrical Systems

10

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

© 2011 Polaris Sales Inc.

Ignition Timing Chart

Convert the ignition timing specification from degrees 

BTDC to either inches or millimeters, then use a dial 
indicator to verify timing marks.

ROD/STROKE (mm)

600 DC-CFI-2/4

128mm ROD / 64mm STROKE

800 DC-CFI-2

132mm ROD / 70mm STROKE

Degrees BTDC

MM

Inches

MM

Inches

1

0.0061

0.0002

0.0067

0.0003

2

0.0244

0.0010

0.0270

0.0011

3

0.0548

0.0022

0.0607

0.0024

4

0.0974

0.0038

0.1078

0.0042

5

0.1522

0.0060

0.1684

0.0066

6

0.2190

0.0086

0.2424

0.0095

7

0.2979

0.0117

0.3298

0.0130

8

0.3889

0.0153

0.4305

0.0169

9

0.4919

0.0194

0.5445

0.0214

10

0.6068

0.0239

0.6717

0.0264

11

0.7336

0.0289

0.8121

0.0320

12

0.8723

0.0343

0.9656

0.0380

13

1.0227

0.0403

1.1321

0.0446

14

1.1849

0.0466

1.3115

0.0516

15

1.3586

0.0535

1.5038

0.0592

16

1.5439

0.0608

1.7089

0.0673

17

1.7406

0.0685

1.9266

0.0758

18

1.9487

0.0767

2.1569

0.0849

19

2.1681

0.0854

2.3996

0.0945

20

2.3986

0.0944

2.6547

0.1045

21

2.6402

0.1039

2.9220

0.1150

22

2.8927

0.1139

3.2013

0.1260

23

3.1560

0.1243

3.4927

0.1375

24

3.4300

0.1350

3.7958

0.1494

25

3.7146

0.1462

4.1106

0.1618

26

4.0096

0.1579

4.4369

0.1747

27

4.3149

0.1699

4.7746

0.1880

28

4.6303

0.1823

5.1235

0.2017

29

4.9558

0.1951

5.4835

0.2159

30

5.2911

0.2083

5.8543

0.2305

31

5.6361

0.2219

6.2358

0.2455

32

5.9907

0.2359

6.6278

0.2609

33

6.3546

0.2502

7.0302

0.2768

34

6.7278

0.2649

7.4427

0.2930

35

7.1099

0.2799

7.8652

0.3097

36

7.5010

0.2953

8.2974

0.3267

37

7.9007

0.3111

8.7392

0.3441

38

8.3089

0.3271

9.1903

0.3618

39

8.7254

0.3435

9.6506

0.3799

40

9.1501

0.3602

10.1198

0.3984

 

 

 

 

 

 

 

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