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Snowmobile Polaris 600 RUSH (2010 year). Manual - part 20

3.30

Engine/Cooling/Exhaust

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

800 DC-CFI-2 Crankcase/Crankshaft

GEAR CLAMPS

ADAPTER PLATE

REED STUFFERS

REED BLOCKS

SEAL GUARD

PTO SEAL

ALIGNMENT DOWELS

MAG SEAL

MAG BEARING

FLYWHEEL KEY

PTO BEARING

WRIST PIN BEARINGS

OIL INJECTION CHECK VALVE QTY. 5

ALIGNMENT DOWELS

STATOR WIRE RETAINER

= T

A: 9 ft-lb (12 Nm)



B: 22 ft-lb (30 Nm) - Apply Loctite® 242™



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

3.31

Engine/Cooling/Exhaust

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

Disassembly and Assembly Process - Crankcase/
Crankshaft

Remove the engine from the engine compartment.

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

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

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.

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

Discard the PTO and MAG crankshaft seals.

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

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

Reinstall the crankshaft back into the lower crankcase
using two new crankcase seals.

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.

10. 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.

11. Liberally coat the crankshaft bearings and

components with Polaris two-stroke engine oil.

800 DC-CFI-2 Crankshaft Identification

Two different crankshaft assemblies (Type 1 and Type 2)
are used for production and service parts. Use the codes
etched into the nose of the PTO end to determine
crankshaft type when ordering service parts.

Type 1 will have the number 3753. Type 2 will have the
number 0262.

DO NOT FILL MAG

BEARING OIL

GALLERY WITH

CASE SEALANT

DOWELS

3.32

Engine/Cooling/Exhaust

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

600/800 DC-CFI Water and Oil Pump

Assembly

OIL PUMP

BEARING

CROSS SHAFT

WASHER

O-RING

SEAL

MECHANICAL SEAL

WASHER

IMPELLER

NUT

WASTER PUMP COVER GASKET

WASTER PUMP COVER

= T

A: 10 ft-lb (13 Nm)



B: 9 ft-lb (12 Nm)



C: 18 ft-lb (Nm) Apply pipe sealant.

3.33

Engine/Cooling/Exhaust

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

Disassembly / Assembly Process

IMPORTANT: Use the mechanical seal installation
tool to install the water pump seal, PN: 2872010.

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

Remove the oil tank/clutch cover assembly, airbox,
exhaust pipe and resonator. Remove the hoses
connected to the water pump cover.

To access the impeller and mechanical seal, remove
the water pump cover. Discard the water pump cover
gasket.

Remove the impeller nut, impeller and washers from
the cross shaft.

Carefully pry the mechanical seal and seal out of the
crankcase.

Water pump assembly is the reverse of disassembly.
Always use new seals and gaskets during assembly.

To remove the oil pump, the engine must be removed
from the engine compartment. Remove the two
fasteners then pull the pump out of the crankcase
bore. Discard the o-ring.

The cross shaft can be extracted from the water pump
side of the crankcase.

Assembly is the reverse of disassembly. Always use
new o-rings, seals and gaskets during assembly.

10. Install a new seal onto the shaft from the water pump

side.

11. To install a new water pump seal, use the seal

installation tool, PN 2872010. Verify the seal lips are
facing the cross shaft gear.

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