Snowmobile Polaris 600 RUSH (2010 year). Manual - part 25

3.50

Engine/Cooling/Exhaust

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

© 2011 Polaris Sales Inc.

EXHAUST SYSTEMS

PRO-RIDE DC-CFI-4 Exhaust System

NOTE:  Always use the stainless steel (gray) springs 
to connect the exhaust pipe to the exhaust manifold.





When removing the exhaust pipe, disconnect the EGT 
probe wire harness. Do not remove the EGT probe 
from the pipe if not necessary.

HEAT SHIELD

 

EXHAUST PIPE

 

ZINC-PLATED (YELLOW) SPRINGS

 

STAINLESS STEEL (GRAY) SPRINGS

 

GASKET

 

HEAT SHIELD

 

A

B

C

D

GASKETS

 

EXHAUST SEAL

 

MOUNT BUMPER

(INSTALL LARGE END TO OUTSIDE)

 

= T 

A: EGT Sensor: 32 ft-lb (44 Nm) Apply anti-seize to 
threads.



B: Exhaust Manifold Fasteners: 22 ft-lb (30 Nm)



C: Silencer Rubber Mount Fastener = 17 ft-lb (23 Nm)



D: Silencer Bracket Fasteners = 26 ft-lb (35 Nm)

3.51

Engine/Cooling/Exhaust

3

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

© 2011 Polaris Sales Inc.

PRO-RIDE DC-CFI-2 Exhaust System

NOTE:  Always use the stainless steel (gray) springs 
to connect the exhaust pipe to the exhaust manifold.




When removing the exhaust pipe, disconnect the EGT 
probe wire harness. Do not remove the EGT probe 
from the pipe if not necessary.

EXHAUST PIPE

 

ZINC-PLATED (YELLOW) SPRINGS

 

STAINLESS STEEL (GRAY) SPRINGS

 

GASKET

 

ISOLATOR

 

A

B

GASKET

 

EXHAUST SEAL

 

ZINC-PLATED (YELLOW) SPRINGS

 

ZINC-PLATED (YELLOW) SPRINGS

 

ZINC-PLATED (YELLOW) SPRINGS

 

CHASSIS GROMMET

 

= T 

A: EGT Sensor: 32 ft-lb (44 Nm) Apply anti-seize to 
threads.



B: Exhaust Manifold Fasteners: 22 ft-lb (30 Nm)

3.52

Engine/Cooling/Exhaust

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

© 2011 Polaris Sales Inc.

Variable Exhaust System (VES)-Threaded Valve

Assembly Notes:

• Replace spring if rusted, bent, or distorted

• Inspect bellows for tears.

• Inspect guillotine threads and cap nut threads for 

wear/galling. Replace parts as required.

• Discard gasket. Replace with new parts during 

assembly.

• Clean components as outlined in Chapter 2-

Maintenance.

EV CAP

SPRING

CAP NUT

BELLOWS

GUILLOTINE

EV BASE

SPACER

GASKET

A

A

B

= T 

EV Cap Screws (A): 10.5-13.5 ft-lb (14.3-18.3 Nm)



Apply Loctite® 242™ to cylinder screws.



Cap Nut (B): 14-18 ft-lb (19.1-24.5 Nm)



Apply Loctite® 242™ to threads.

3.53

Engine/Cooling/Exhaust

3

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

© 2011 Polaris Sales Inc.

Variable Exhaust System (VES)-Threaded Stud

Assembly Notes:

• Replace spring if rusted, bent, or distorted

• Inspect bellows for tears.

• Inspect threaded stud, cap, guillotine threads and 

cap nut threads for wear/galling. Replace parts as 
required.

• Discard gasket. Replace with new parts during 

assembly.

• Clean components as outlined in Chapter 2-

Maintenance.

Special Tool:

Use special tool: PS-50753 to disassemble the cap nut, 
bellows and threaded stud/washer assembly.

To disassemble guillotine components, clamp blade in 

soft-faced bench vise. Loosen cap nut.

If the complete assembly un-screws from the guillotine, 
use special tool PS-50753 to clamp the threaded stud/
washer in the bench vise.

During reassembly, apply Loctite® 242™ to the threaded 
stud/washer guillotine and cap nut threads. Loosely 
install the threaded stud/washer, bellows, and cap nut. 
Torque only cap nut to specification to fasten all 
components.

NOTE:  A new threaded stud/washer has pre-applied 
thread lock. No Loctite® is required.

EV CAP

SPRING

CAP NUT

BELLOWS

GUILLOTINE

EV BASE

THREADED STUD/WASHER

GASKET

= T 

EV Cap Screws(A): 10.5-13.5 ft-lb (14.3-18.3 Nm)



Apply Loctite® 242™ to cylinder screws.



Cap Nut/Threaded Stud Asm.(B): 18-22 ft-lb



(24.5-29.9 Nm) Apply Loctite® 242™ to threaded 
stud threads.

VES Threaded Stud/Cap Tool

PS-50573