Snowmobile Polaris 600 RUSH (2010 year). Manual - part 22

3.38

Engine/Cooling/Exhaust

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

Engine Installation

Clean the engine compartment.

Inspect engine mounts for damage. Replace mounts
or radial inserts at this time. If any mount bracket was
removed, reinstall and torque screws to specification.

Verify cooling hose and starter motor power cable
(electric start models) are secured to the bulkhead
floor with a p-clamp.

NOTE: White tape on wire harnesses and hoses
designates clamp/harness retainer location.

Visually inspect the oil pump setting. If adjustment is
required, adjust the oil pump before installing the
engine.

With the help of an assistant of engine hoist, lower the
engine into the bulkhead.

Spray the radial inserts on each of the four engine
mounts with rubber lubricant or isopropyl alcohol.
Lubricating the radial inserts will prevent the engine
fasteners from catching on the rubber when they are
torqued.

Install all four engine mount screws by hand. Once all
four are installed, torque screws to specification.

Install the torque link adjuster using a new lock nut.
Torque lock nut and screws to specification.

Reinstall the surge tank-to-water pump and heat
exchanger-to-water pump hoses on to the water
pump cover.

10. Reinstall the coolant outlet and bypass outlet hoses

at the thermostat housing. Open the bleed slightly to
allow air to escape when the engine is filled with
coolant.

11. If the snowmobile is equipped with electric start,

reinstall the starter worm drive shaft, and the starter
motor.

12. Reinstall the exhaust gaskets and y-pipe. Torque y-

pipe fasteners to specification.

13. Reinstall the throttle cable. Verify the throttle cable

freeplay is set to specification.

14. Install the MAG and PTO exhaust valve assemblies

using new gaskets. Torque fasteners to specification.
Reconnect vent hoses and secure clamps.

15. Reinstall the lower steering shaft bushing bracket on

to the over structure by loosely installing the two
screws. Torque fasteners to specification.

= T

Engine Mount Bracket: 22 ft-lb (30 Nm)

= T

Engine Mount Screws: See Page 3.20.

= T

Torque Link Nut/Screws: 26 ft-lb (35 Nm)

= T

Exhaust Y-Pipe Screws: 22 ft-lb (30 Nm)

= T

Exhaust Valve Mounting Screws: 2 ft-lb (16 Nm)



Apply Loctite® 242™

= T

Lower Steering Shaft Bushing Bracket:



15 ft-lb (20 Nm)

GASKET

EV ASSEMBLY

FASTENERS

3.39

Engine/Cooling/Exhaust

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

16. Reinstall the steering drag link with the rod ends

parallel to each mating surface. Torque nuts to
specification.

17. If the snowmobile is equipped with electric start,

reinstall the battery and reconnect the battery cables.
Connect BLACK negative (-) cable first, and then RED
positive (+) cable last.

18. Reinstall the exhaust silencer. Verify the silencer

outlet tube is installed in the fender boot and that the
boot has not been pushed out of the fender.

19. Torque the silencer rubber mount fastener to

specification.

NOTE: Install the silencer mount rubber dampener
with the fat end facing outwards.

20. Reinstall the exhaust pipe. Verify the gray springs are

installed at the pipe-to-manifold locations.

21. Reconnect the over structure electrical component

wire harness connections. Verify the white harness
bands are routed so they can be fitted into each
respective harness retainers.

22. Clean the PTO clutch taper with emery cloth. Reinstall

the drive clutch. Torque fastener to specification.

= T

Steering Drag Link Rod End Nuts: 37 ft-lb (50 Nm)

CAUTION

Attach the BLACK (-) battery cable first, and then the
RED (+) cable last.

= T

Silencer Mount: 17 ft-lb (23 Nm)

= T

Drive Clutch Bolt Torque: 80 ft-lb (108 Nm)



Re-torque after running engine.

SILENCER MOUNT

3.40

Engine/Cooling/Exhaust

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

23. Reinstall the driven clutch assembly. Torque fastener

to specification.

24. Reinstall the drive belt.

25. Reinstall the airbox assembly. See “Air Box Servicing”

on page 2.23.

26. Reinstall the clutch cover/oil tank assembly. See “Oil

Tank/Clutch Cover Service” on page 2.14.

27. Fill the coolant surge tank with 60/40 Polaris engine

coolant. Follow the Cooling System Fill/Bleed
Procedure outlined in Chapter Two. See “Cooling
System Bleeding” on page 2.10.

28. Reinstall the hood assembly. See “Door/Hood

Removal and Installation” on page 2.24.

29. Reinstall the left and right door panels.

30. If the engine was rebuilt, follow the engine break-in

procedure. See “Engine Break-In Procedure” on
page 2.6.

= T

Driven Clutch Bolt Torque: 18 ft-lb (25 Nm)

3.41

Engine/Cooling/Exhaust

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

COOLING SYSTEM

Thermostat Replacement

Remove the housing cover, by removing the cover
bolts.

Check the gasket condition and replace if damaged.

Replace the thermostat. Make sure that the spring
side is facing downward or toward the engine.

Replace cover. Torque the cover fasteners to
specification.

Verify the bleed screw and washer are installed.

Thermostat Orientation

The thermostat must be installed in the cylinder head has
shown in the illustrations.

Center Thermostat Location

Offset Thermostat Location

800 Thermostats

There are two different thermostats used depending on
what model the engine is installed in.

Both thermostats are full open at 120



F (49



C).

CAUTION

Allow engine to cool completely before working with the
engine cooling system.



Engine coolant can be under pressure and hot.
Escaping steam and/or coolant may cause severe
burns to exposed skin.

= T

Cover Fasteners: 9 ft-lb (12 Nm)

BLEED SCREW

WASHER

HOUSING COVER

THERMOSTAT

GASKET

Cooling System Type Thermostat PN Bleed Hole ID

RUSH/Switchback

7052433

2 mm

SB Assault/RMK



PRO RMK/



RMK Assault

7052452

3.5 mm

BRIDGE ALIGNED WITH HOLES

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