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Snowmobile Polaris 600 RUSH (2010 year). Manual - part 41

5.6

Final Drive/Brake System

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

Full Assembly View

REFERENCE

DESCRIPTION

Brake Disc Fastener

Phantom Caliper Models = Flat Washer



Phantom Lite Caliper Models = Domed
(Beveled) Washer

Brake Disc

Seal Sleeve

Jackshaft O-Ring

Seal

Bearing

Cover Fasteners

Cover

Chaincase Sleeve

Cover Gasket

Top/Bottom Gears

Chain

Snap Rings

Bearings

Chain Tensioner/Wear Pad

Tensioner Adjustment Screw/Jam Nut

Vent

Fill/Drain Plugs

Alignment Dowels

Seals

Dome (Beveled) Washer

Float Washer



2010 = (To get .8mm disc float = 1-2 QTY.)



2011-Current= (1 QTY.)



Phantom Lite Brake Caliper = (1 QTY.)

Wave Washer



2011-Current Phantom Caliper Models

REFERENCE

DESCRIPTION

5.7

Final Drive/Brake System

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

Chaincase Disassembly

Remove the left and right door panels. Remove the
screw securing the right lower fender to the chassis.

Remove the hood assembly.

Remove the exhaust silencer.

If equipped with electric start, remove the battery and
battery box.

Place a drain pan under the chaincase. Remove the
plug to drain the oil. Clean the plug threads. Verify the
o-ring is not damaged.

Reinstall plug and torque to specification.

Apply the parking brake and then loosen the brake
disc mounting fastener.

Release the parking brake. Remove the brake calliper
mounting bolts. Tie the caliper to overstructure.

NOTE: DC-CFI-2 models with Phantom brake calipers
have washers in place of silencer bracket. Phantom
Lite models do not use washers or bracket.

Remove the brake disc from the jackshaft. Reference
table for brake disc hardware.

10. Note the groove on the seal sleeve. Use a pair of flat

blade screwdrivers or soft-jawed pliers to carefully pry
the sleeve out of the cover.

11. Locate the o-ring on the end of the jackshaft inside the

cover. Use a pick and carefully remove the o-ring.
Inspect o-ring and discard if damaged or torn.

CAUTION

Remove the RED (+) battery cable first, and then the

BLACK (-) cable last. Reverse order when attaching

cables to battery.

= T

Chaincase Drain Plug: 8-9.5 ft-lb (8-13 Nm)

CAUTION

Do not allow the brake caliper to hang by the brake hose.

O-RING

BRAKE CALIPER

SILENCER BRACKET

YEAR

CALIPER

TYPE

BRAKE

DISC

FASTENER

HARDWARE

2010/

Phantom

Fastener: 29 ft-lb (40 Nm)



Flat Washer



1-2 Float Washers



(Install QTY. to achieve .8mm Disc Float)

2011-Current/

Phantom

Fastener: 40 ft-lb (54 Nm)



Flat Washer



Wave Washer



1 Float Washer

2011-Current/

Phantom Lite

Fastener: 40 ft-lb (54 Nm)



Domed (Beveled) Washer (Dome facing out.)

See Table

O-RING

5.8

Final Drive/Brake System

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

12. Remove the cover fasteners.

13. Carefully remove the cover. Use a flat blade

screwdriver at the pry points to aid removal.

14. After removing the cover, note the two dowels in the

chaincase.

15. Inspect the cover gasket for damage. Inspect the

bearing and seal in the cover. Replace bearing if it no
longer rolls smoothly. Replace the seal if damaged.

16. Remove the chaincase sleeve from the jackshaft.

17. Remove the lower gear screw. Note the beveled

washer orientation.

18. Loosen the chain adjuster screw. Remove the

tensioner pad, upper and lower gears, and chain.

Chaincase Assembly

Thoroughly clean the chaincase, gears, and chain.

Inspect the tensioner pad for damage. Replace if
excessive wear is evident.

Install the gears and chain as a set.

Install the lower gear screw and beveled washer.
Verify the beveled washer is installed dome side out.

Torque screw to specification.

Rotate the driven clutch forward to move all of the
chain slack to the tensioner side.

Install the chain tensioner. Tighten the tensioner
screw until there is 1/8" (3.175mm) chain deflection on
the backside of the drive chain.

Verify the tensioner screw washer is seated against
the chaincase, and then torque the tensioner screw
jam nut to specification.

Install the chaincase sleeve on to the jackshaft.

10. Inspect the cover gasket. Replace if cut or torn. Verify

the gasket is installed flush in the cover.

11. Install the cover making sure the cover engages the

two dowels evenly.

12. Lightly tap on the cover with a soft-faced hammer to

seat the cover.

O-RING

SEAL SLEEVE

COVER

PRY POINT

SLEEVE

DOWEL

TENSIONER ADJUSTER

= T

Lower Gear Fastener: 29 ft-lb (40 Nm)

= T

Tensioner Jam Nut: 21 ft-lb (28 Nm)

GEARS/CHAIN

5.9

Final Drive/Brake System

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

13. Install the cover screws. Torque screws to

specification using the specified sequence. See
“Chaincase Cover Torque Pattern” on page 5.5.

14. Install the o-ring on to the jackshaft. Verify the o-ring

is sitting in the groove. Install the seal sleeve with the
groove facing out.

15. Clean the brake disc with brake cleaner and then

install on to jackshaft.

16. Install the specified brake disc hardware as shown in

the table.

17. Install the brake caliper and silencer bracket if

equipped. Torque fasteners to specification.

18. Set the parking brake. Torque the brake disc screw to

specification. Release the parking brake.

19. If equipped with electric start, reinstall the battery box,

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

20. Install the exhaust silencer. Verify the outlet boot is

installed correctly around the silencer outlet tube.

21. Install the screw securing the right fender to the

chassis. Reinstall the hood assembly and both door
panels.

22. Refill the chaincase with synthetic 80W lubricant. Fill

to specification or when lubricant reaches the fill plug
bore opening.

= T

Cover Fasteners: 9.5 ft-lb (13 Nm)

YEAR

CALIPER

TYPE

BRAKE

DISC

FASTENER

HARDWARE

2010/

Phantom

Fastener: 29 ft-lb (40 Nm)



Flat Washer



1-2 Float Washers



(Install QTY. to achieve .8mm Disc Float)

2011-Current/

Phantom

Fastener: 40 ft-lb (54 Nm)



Flat Washer



Wave Washer



1 Float Washer

2011-Current/

Phantom Lite

Fastener: 40 ft-lb (54 Nm)



Domed Washer (Dome facing out.)

= T

Brake Caliper Fasteners: 40 ft-lb (54 Nm)

= T

Brake Disc Fastener:



2010: 29 ft-lb (40 Nm)



2011-Current: 40 ft-lb (54 Nm)

Content .. 39 40 41 42 ..