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Snowmobile Polaris 600 RUSH (2010 year). Manual - part 14

3.6

Engine/Cooling/Exhaust

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

Vehicle/Engine Matrix

MODEL

YEAR

VEHICLE

ENGINE

MODEL

NUMBER

2010

600 Rush

S4202-6044-OP6N

2011

600 Rush/Rush LX/Rush Pro-R

S4215-6044-OO6N

800 Rush/Rush LX/Rush Pro-R

S4139-8044-OO8G

800 Switchback 1.3/2.0

800 RMK 155

S4229-8044-OO8G

800 RMK Assault

800 PRO RMK 155/163

S4092-8044-OO8G

2012

600 Rush/Rush Pro-R/600 Switchback/Adventure/Switchback Pro-R

S4357-6044-OL6N

800 Rush/Rush Pro-R/Pro-R LE/800 Switchback/Switchback Pro-R

S4360-8044-OL8G

Switchback Assault 1.3/2.0

800 RMK 155

S4361-8044-OL8G

600 RMK 144/155

S4316-6044-OL6G

600 PRO RMK 155

S4452-6044-OL6G

800 RMK Assault

800 PRO RMK 155/163

S4359-8044-OL8G

3.7

Engine/Cooling/Exhaust

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

SPECIAL TOOLS

Special Tools - Engine

NOTE: Polaris dealers can order the tools listed
above through the SPX Service Tools catalog or by
calling SPX @ 1-800-328-6657.

ENGINE INSPECTIONS

Cylinder Head Inspection

Using a precision straight edge and a feeler gauge, to
inspect cylinder head for warping. Replace head if
warping exceeds .006" (.015mm).

Special Tools - Engine

PART

NUMBER

DESCRIPTION

NOTE

2870303-A

Ammco Hone Kit

Use to re-surface cylinder walls
when installing new piston and/or
rings.

2870588

Hone Oil

Provides better crosshatch
pattern when honing cylinders.

PU-49876

Ammco 320 Grit Stone

Use to re-surface plated big bore
cylinders.

2870390

Piston Support Block

Supports piston when installing
pin and c-clips.

2871043-A

Flywheel Puller

PU-45255

22mm Piston Pin Puller

800 CFI Engines

PS-47055

Offset Piston Pin Puller
Adapter

800 CFI Engines

2870386

Piston Pin Puller

2871445

Pin Puller Adapter

Use with 2870386.

2871989

Engine Mount Socket

Removes tabbed rubber engine
mounts.

2872389

Water Pump Seal
Installation Tool

Used to install water pump seal
on all 600/700/ 800 engines.

2872401-A

20mm C-Clip Tool

Install c-clips on all 600 / 700
engines.

2872622A

22mm C-Clip Tool

Install c-clips on all 800 engines.

PS-49001

Oil Cable Wrenches

Use to loosen or tighten oil pump
cable jam nuts.

2870630

Battery Powered Timing
Light

Check ignition timing.

2870852

14mm Compression
Gauge

PU-45149

Hose Pincher

PU-45419

Strap Wrench

Secure drive clutch or flywheel.

PU-45423

Telescoping Gauge Set

Use to inspect cylinder bore
diameter.

PU-45424

Dial Indicator Set

Use to measure run-out, piston
degrees-to-TDC, etc.

PV-39776

Electronic Digital Caliper

PU-45433

Seal Pick Set

PU-45431

Depth Micrometer Set

PV-34673

Precision Straight Edge

PV-43554

V-Block Set

PV-3009

75 - 100mm Micrometer

Use to measure piston diameter,
etc.

PS-50753

VES threaded stud/cap
tool.

Use to clamp VES threaded stud/
cap in bench vise.

= In. / mm.

Cylinder Head Warp Limit

.006" (.015mm)

3.8

Engine/Cooling/Exhaust

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

Cylinder Measurement

Inspect cylinder for wear, scratches, or damage. If no
damage is evident, measure the cylinder for taper and out
of round with a dial bore gauge. Measure the bore 20mm
from the top of the cylinder; in line with the piston pin and
90° to the pin to determine if the bore is out of round.
Repeat the measurements at a point just above the
exhaust port and at a point below the transfer port. Use the
chart below and record all measurements.

NOTE: A dial bore gauge is the only recommended
tool to accurately measure cylinder bore diameter.

Cylinder Measurement Worksheet

TOP (Measured 20mm from top of cylinder)

MIDDLE (Measured above exhaust port)

BOTTOM (Measured below transfer port)

Out-of-Round = Top X - Top Y and Bottom Y - Bottom X

Taper = Top Y - Bottom Y and Top X - Bottom X

= In. / mm.

Taper Limit: .002" (0.051mm)



Out-of-Round Limit: .002" (0.051mm)

3.9

Engine/Cooling/Exhaust

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

Piston Inspection

Check piston for scoring or cracks in piston crown or pin
area. Excessive carbon buildup below the ring lands is an
indication of piston, ring or cylinder wear.

Using only a micrometer, measure the piston outside
diameter at a 90° angle to the direction of the piston pin
and at the specified measuring point.

NOTE: A micrometer is the only recommended tool to
accurately measure piston diameter.

Subtract this measurement from the minimum cylinder
measurement (90° to the pin). If clearance exceeds the
service limit piston/cylinder overhaul may be required.

Piston Ring Installed Gap

Position the ring 20mm from the top of the cylinder using
the piston to push it squarely into place. Measure installed
gap with a feeler gauge at both the top and bottom of the
cylinder.

NOTE: A difference in end gap indicates cylinder
taper. The cylinder should be measured for excessive
taper and out-of-round. Replace rings if the installed
end gap exceeds the service limit. Always check
piston ring installed gap after re-boring a cylinder or
when installing new rings.

Piston rings are installed with marking or beveled side up.

= In. / mm.

Measuring Point



600/800 Pistons: 10-20mm

MEASURING

POINT

Content .. 12 13 14 15 ..