Snowmobile Polaris 600 RUSH (2010 year). Manual - part 21

3.34

Engine/Cooling/Exhaust

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

© 2011 Polaris Sales Inc.

Oil Hose Routing

TEE FITTING

3.35

Engine/Cooling/Exhaust

3

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

© 2011 Polaris Sales Inc.

Engine Removal

NOTE: Inspect all parts for wear or damage during 
disassembly. Replace all seals, o-rings, and gaskets 
with Genuine Pure Polaris parts during assembly. 

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
Torx screws are used throughout the engine 
compartment. Always use good-quality Torx 
wrenches when removing or installing these screws. 
Do not use worn or damaged tools.

1.

Remove the left and right door panels. Remove the 
hood assembly.

2.

Remove the drive belt, fender screw, drive clutch, and 
driven clutch.

3.

Remove the oil tank/clutch cover assembly.See “Oil 
Tank/Clutch Cover Service” on page 2.14.

4.

Remove the exhaust pipe, and exhaust silencer.

NOTE: Disconnect the exhaust temperature sensor 
probe wiring harness. Do not remove probe from pipe 
unless service is required.

5.

If the snowmobile is equipped with electric start, 
disconnect the battery. Remove the starter motor from 
the motor bracket. Remove the worm drive shaft from 
the case-mounted drive gear.

6.

Remove the two screws securing the lower steering 
shaft bushing clamp shaft to the over structure.

FENDER SCREW

CAUTION

Remove the RED (+) battery cable first, and then the 
BLACK (-) cable last. Reverse order when attaching 
cables to battery.

(+) CABLE

STARTER MOTOR

MOUNTING NUT

MOUNTING NUT

3.36

Engine/Cooling/Exhaust

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

© 2011 Polaris Sales Inc.

7.

Remove the upper steering drag link from the lower 
steering shaft.

8.

Remove the airbox assembly.See “Air Box Servicing” 
on page 2.23.

9.

Remove the fuel supply and return hoses between the 
fuel tank and fuel rail mounted to the engine.

10. Remove the surge tank cap. Extract the engine 

coolant with a siphon or wet/dry vacuum.

11. Remove the thermostat bypass and main outlet hoses 

from the thermostat housing.

12. Remove the coolant return hoses from the water 

pump cover.

13. Disconnect the throttle cable from the throttle body.

14. Cut the knot at the end of the recoil rope to remove 

the handle. Pass the recoil rope through the console 
and guide. Tie the recoil rope in a knot to prevent it 
from retracting into the recoil housing.

15. Disconnect the engine torque link by removing the two 

screws securing the bracket to the bulk, and then the 
torque link lock nut.

NUT ON BACKSIDE

3.37

Engine/Cooling/Exhaust

3

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

© 2011 Polaris Sales Inc.

16. Remove the exhaust y-pipe from the engine using a 

ball-end Allen wrench. Remove the exhaust gaskets. 
If un-damaged, they can be re-used during assembly.

17. Remove the PTO and MAG exhaust valve assemblies 

from the cylinder. Doing this will provide clearance 
between the engine and bulkhead so the engine can 
be removed from the PTO-side of the engine 
compartment.

18. Remove the two engine mounting screws from the 

PTO-side of the engine.

19. Remove the two engine mount screws from the MAG-

side of the engine.

NOTE:  Use a six to eight inch extended Allen wrench 
to access the MAG-side engine mounting bolts.

20. With the help of an assistant carefully remove the 

engine from the PTO-side of the engine compartment.

21. Use care when lifting the engine up and over the 

tunnel and side support plate. Do not damage the oil 
pump when pulling the engine out.