Snowmobile Polaris 600 RUSH (2010 year). Manual - part 50

6.16

PVT System

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

© 2011 Polaris Sales Inc.

Adjusting Engine Mount Bolts/Engine 

Alignment

Minor adjustments to the engine mount bolts and MAG-
front engine mount can be performed if the alignment tool 
indicates major clutch mis-alignment.

1.

Loosen, but do not remove, the four engine mount 
bolts.

2.

Loosen, but do not remove, the two Torx screws 
securing the MAG-front engine mount to the 
bulkhead.

3.

Verify clutch alignment has changed using the Clutch 
Alignment Tool part number: PS-47477. The engine 
can be moved slightly with the screws loosend at the 
MAG-front location.

4.

Once clutch alignment is set, tighten the engine mount 
bolts to specification in the sequence shown in the 
illustration.

5.

Torque the two Torx screws only after all four engine 
mount bolts are torqued to specification.

6.

Re-check clutch alignment. If clutch alignment is still 
incorrect, inspect the engine mounts, motor straps, 
radial inserts, and chassis for broken or twisted 
components.

= T 

2010 - 14mm Head Diameter - DK.Green Color



DK. GREEN-M10x1.5x45 (8.8): 30 ft-lb (41 Nm)




2011 - 14mm Head Diameter - Silver/Gray Color



SILVER/GRY-M10x1.5x50 (12.9): 35 ft-lb (48 Nm)




2012/Replacement Kit - 16mm Head Diameter



Silver/Gray Color



SILVER/GRY-M10x1.50 (12.9): 40 ft-lb (54 Nm)

= T 

Front-MAG Engine Mount Screws-to-Bulkhead 
Screws: 22 ft-lb (30 Nm)

1

2

3

4

6.17

PVT System

6

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

© 2011 Polaris Sales Inc.

DRIVE CLUTCH

Identification

Every clutch will have the clutch part numbers etched on 
to the cover (A). The “X" (B) marking is an index mark 
where the clutch cover (C), clutch spider (D) and the 
stationary sheave (E) should line up when the clutch is 
assembled.

Drive Clutch Removal 

NOTE:  All clutch tools can be found at the beginning 
of this chapter. 

1.

Remove the belt.

2.

Place the clutch holding tool (PN 9314177-A) on the 
drive clutch.

3.

Remove the drive clutch retaining bolt. Note the 
placement and number of washers on retaining bolt.

4.

Insert the correct clutch puller into the retaining bolt 
hole.

5.

Tighten the puller into the clutch. If the clutch does not 
come off, strike the clutch puller head with a hammer. 
If the clutch does not “pop” off, continue to tighten the 

clutch puller, and repeat this step.

A

B

C

D

B

E

CAUTION

Do not use an impact wrench to remove or install the 

clutch bolt or clutch puller. Damage to the clutch and/or 

crankshaft can occur.

6.18

PVT System

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

© 2011 Polaris Sales Inc.

Drive Clutch Disassembly

1.

In a straight line, mark/etch the sheaves and the cover 
with a black marker or a scribe. 

2.

Place the drive clutch in the clutch compression tool 
(PN 8700220).

3.

Compress the clutch in the compression tool, then 
secure the chain.

4.

Evenly remove the cover fasteners. The cover 
bushing may be damaged if the cover is side-loaded 
or mis-aligned.

5.

Carefully remove the tension from the compression 
tool.

6.

Remove the cover and inspect the cover bushing. 
Replace if damaged or worn.

NOTE: Replace the cover bushing if the inside 
diameter is over 1.40

 (28.95mm)

7.

Remove the spring.

8.

Mount the drive clutch securely in a drive clutch 
holding fixture (PN 2871358).

9.

Remove the jam nut in a counterclockwise direction 
(standard thread) using the drive clutch spider nut 
socket (PN 2871358).

10. Install the spider removal tool (PN 2870341), and 

remove the spider in a counterclockwise direction 
(standard thread).

11. Measure the total thickness of the spacer washers 

that are installed on top of the clutch spacer. Record 
the thickness of these spacer washers.

12. Inspect both sheave surfaces for wear or damage.

13. Inspect the moveable sheave bushing for wear or 

damage.

14. Remove all three drive clutch weights.

15. Inspect each weight. The surface should be smooth, 

with no waves or galling. Place pin inside weight to 
check flyweight bushing and pin surface for wear by 
rocking the weight back and forth.

16. Inspect all the rollers, bushings and roller pins by 

pulling a flat metal rod across the roller.

17. Roller can also be inspected by rolling with a finger to 

feel for flat spots, roughness, or loose bushing.

NOTE: The flyweight bushing is not replaceable. If 
flyweight bushing is damaged both the flyweight, pin 
and nut will need to be replaced. 

18. Inspect to see if the roller and bushing are separating.

19. Bushing must fit tightly in roller.

20. Replace roller and pin if roller fails to roll smoothly (no 

flat spots) or if the bushing is loose or worn.

STATIONARY SHEAVE

MOVEABLE SHEAVE

SPIDER

COVER

SPRING

JAM NUT

SPACERS

CLUTCH SPACER

BEARING SLEEVE

MOVEABLE INSERT

COVER BEARING

RETAINER

SPIDER BUTTON

WASHER

ROLLER

ROLLER PIN

SHIM

WEIGHT

WEIGHT PIN

CAUTION

Wear eye protection when servicing the drive clutch.

Sheaves must be marked to provide a reference point 

for clutch balance and spider indexing. If the sheaves 

are not marked and the spider washers are changed or 

misplaced, the clutch may be out of balance and 

damage to the clutch may result. 

WARNING

Clutch spring is under extreme tension, use caution and 

wear eye protection when disassembling the clutch.

6.19

PVT System

6

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

© 2011 Polaris Sales Inc.

Roller Removal

1.

With the spider in a vise start removing the spider 
buttons by drilling a 0.18" hole in the center of a button 
on one side of the spider.

2.

Place a pin punch through the drilled hole in the button 
and drive the opposing button and pin out.

3.

Remove shims (if any are installed) and note their 
location.

4.

Flip the spider over and tap out the holed button.

5.

Perform steps on remaining spider legs.

NOTE:  When required, button shims are installed on 
the trailing (right) side of the spider leg as viewed from 
the front of spider.

Roller Installation

NOTE:  Use care to start the pin straight. Aluminum 
burrs could pass through into the roller bushing 
causing it to bind and stick. Also use care to make 
sure the roller remains aligned when the pin is driven 
through. The roller busing could be damaged causing 
premature wear and roller failure.

1.

Drive pin into the spider leg .100" -.125" (0.25 - 
0.32cm) beyond the first land of the spider leg.

2.

Install one washer on the portion of the pin that is 
protruding from the spider leg.

3.

Place roller in spider leg and center it on the pin.

4.

Place a second washer on the other side of the roller.

5.

Place the spider on a vise.

6.

Install pin centering tool (PN 2870401).

7.

Drive the roller pin through the second land of the 
spider.

8.

Repeat process for the other two rollers.

Spider Button Installation

1.

A shim kit is available which contains an assortment 
of shims.

2.

Measure the width of the moveable sheave towers 
and record. Specification is 1.50"+/- .001" (38.1mm).

3.

Measure the width of each corresponding spider leg 
with the buttons installed and record. Specification is 
1.496"+/- .001" (37.99mm).

4.

Subtract the spider measurement form the tower 
measurement. The clearance between the spider 
buttons and the moveable sheave towers is .001" - 
.002" (.025 - .05mm).

5.

Add shims beneath each trailing side spider button to 
obtain the specified button-to-tower clearance when 
assembled at each spider leg.

SPIDER

BUTTON

SHIM

WASHER

ROLLER

ROLLER PIN

WASHER

BUTTON

Drive Clutch Shim Kit

PN 2200387

= In. / mm. 

Button-To-Tower Clearance
.001" - .002" (.025 - .05mm)