Snowmobile Polaris 600 RUSH (2010 year). Manual - part 51

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

Bushing/Insert Replacement

The drive clutch moveable sheave and cover bushings/
insert are replaceable. Bushing/insert removal and
installation can be aided using Bushing Removal and
Installation Kit.

The kit uses the Piston Pin Puller tool. Each of the
adapters and/or tools are marked with an item number.
The item number is referenced within the text for
identification.

Moveable Sheave Bushing/Insert Removal

and Installation

NOTE: A torch may be required to release the
bushing retaining compound.

Disassemble the clutch and remove the moveable
sheave from the stationary shaft.

Install handle end of the piston pin puller securely into
a bench vise.

Install the main adapter (Item 8) onto the puller.

Working from inside of moveable sheave, insert the
moveable sheave removal tool (Item 1) into the center
of the sheave. Slide sheave onto puller tool with
towers facing upwards.

Secure puller nut. turn puller barrel to increase tension
on the sheave if required.

Turn sheave counterclockwise on puller rod until it
comes free.

Remove the sheave from the puller tool rod.

Remove and discard the old bushing and insert.

To install a new bushing, place the main adapter (Item
8) onto the puller rod.

10. Apply a thin film of Loctite® 648 to the leading edge

of the new bushing. Push a new bushing into center
of sheave by hand.

NOTE: Verify no retaining compound is deposited on
the I.D. of the bushing.

11. Insert installation tool (Item 1) into center of sheave

and with the towers pointing toward the vise (down),
slide the sheave onto the puller rod.

12. Secure rod nut. turn barrel to apply additional tension

against sheave if required.

13. Turn the sheave counterclockwise until bushing is

fully seated.

14. Remove the rod nut and installation tool and repeat

steps 11 to 13 and install the new insert.

Cover Bushing

NOTE: A torch may be required to release the
bushing retaining compound.

On covers utilizing a retaining ring, remove the ring
using a pick or scribe.

Install the main adapter (Item 8) onto the puller tool.

From outside of the cover, insert the removal tool
(Item 3) into the cover bushing.

With the inside of the cover facing the vise, slide the
cover onto the puller.

Secure the rod nut. Turn the puller barrel to apply
tension if required.

Turn the clutch cover counterclockwise until the
bushing is removed and the cover comes free.

Remove the tools and discard the bushing.

To install a new cover bushing, apply Loctite® 648 to
the leading edge of the new bushing. Insert the new
bushing and bushing installation tool (Item 3) from the
inside of the cover.

NOTE: Verify no retaining compound is deposited on
the I.D. of the bushing.

With the main adapter (Item 8) installed on the puller,
insert the cover onto the puller rod with the outside of
the cover facing the vise.

10. Secure the rod nut and tighten the puller barrel to

apply more tension if required.

11. Turn the clutch cover counterclockwise on the puller

rod until the bushing is fully seated. Remove the tools
from the rod and remove cover.

12. Squeeze the ends of the retaining ring and reinstall

into the back of the cover.

Clutch Bushing Removal / Installation Kit

PN 2871025

Individual Parts:

P-85 Bushing / Insert Tool = 5020627 (Item 1)

Cover Bushing Tool = 5020629 (Item 3)

Main Puller Adapter = 5020632 (Item 8)

Piston Pin Puller Tool

PN 2870386

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

Clutch Assembly

Assemble the rollers, bushings and roller pins if they
were removed.

Install the head of the weight pin so that it is on the
leading side of rotation. This will orientate the nut on
the trailing side of rotation.

Torque weight pin to specification.

Place the moveable sheave onto the stationary
sheave.

Place the same number of spacers on top of the
stepped spacer onto the shaft of the stationary
sheave.

Thread the spider onto the stationary sheave shaft.

Index the spider. See “Spider Indexing” on page 6.22.

Apply Loctite® 243™ to shaft threads. Do not get
Loctite® on moveable bushing. Using the spider tool
(PN 2870341) torque to specification.

Apply Loctite® 243™ to shaft threads. Do not get
Loctite® on moveable bushing.Install the jam nut onto
the shaft and torque it to specification.

10. Place the drive spring on the shaft.

11. Place the cover onto the clutch and torque the cover

fasteners to specification.

NOTE: Do not allow side loading or mis-alignment of
the cover or the bushing may become damaged.

Belt-to-Sheave Clearance Adjustment

Belt-to-sheave clearance is an important factor when
evaluating drive clutch performance as it controls the
starting drive ratio and the position of the drive clutch
weights in relation to engine RPM.

If the clearance is too small, the drive belt will drag on the
face of the sheaves when the engine is at idle speed.

If the clearance is too large, the belt will slip during initial
engagement causing belt burning and low-speed engine
bogging.

Belt-to-sheave clearance can be adjusted by installing a
different drive belt, or by adding or removing shims
washers) located under the spider assembly.

To measure belt-to-sheave clearance, follow these steps:

Verify the drive clutch sheave faces are clean and the
drive belt is in good condition, and not damaged or
excessively worn.

Push the drive belt tight against one side of the drive

= T

Weight Pin Torque:



20-30 in-lb (2.2-3.4 Nm)

= T

Spider Torque:



280-300 ft-lb (380-406 Nm)



Apply Loctite® 243™ to Threads

JAM NUT

SPACER(S)

CLUTCH SPACER

SPIDER

= T

Spider Jam Nut Torque:



290-330 ft-lb (394-447 Nm)



Apply Loctite® 243™ to Threads

= T

Cover Fastener Torque:



100 in-lb (11 Nm) Use cross pattern.

= In. / mm.

Belt-to-Sheave Clearance:



Nominal = .020in. (0.508mm)



Range = .005 - .035in. (0.127 - 0.89mm)

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

clutch sheaves. Measure the opposite side gap using
a feeler gauge.

A slight drag should be felt when inserting the feeler
gauge between the belt and sheave face.

Compare measured gap to the specification.

The distance between the moveable and stationary clutch
sheaves and thus the belt-to-sheave clearance is
determined by the number and thickness of the washer(s)
installed between the spider and clutch spacer.

To increase the clearance, add or install thicker washer(s).
To decrease the clearance, remove or install thinner
washer(s). Either way, belt-to-sheave clearance
adjustment most often requires the spider to be “re-
indexed”.

Spider Indexing

NOTE:

Spider indexing effects belt to sheave

clearance and clutch balance. Please read all
procedures before proceeding.

Remove and disassemble clutch

Add or remove spider washers as required to achieve
desired belt-to-sheave clearance. Make sure that the
stepped washer (A) is on the bottom of the spacer
stack (B). For example: If belt to sheave clearance is
.020

 too large, removing one .020 shim will position

the movable sheave closer to the fixed sheave
reducing belt to sheave clearance by .020

.

NOTE: Install the clutch spacer (stepped washer)
with the lip facing the spider.

Place the correct number of spacer washers (B)
between the spider and clutch spacer (A) (stepped
washer). The following washers are available for fine
tuning:

• 5210752 - .020

 (.51mm)

• 5242981 - .025

 (.63mm)

• 5210753 - .032

 (.81mm)

• 5210754 - .050

 (1.27mm)

Install spider washer(s) and spider aligning the “X”
with the moveable sheave’s “X”. Notice as the spider
seat location is changed, the sheave marks made
before disassembly no longer align (C). There are two
ways to bring the sheave marks into alignment.

Vary the amount and thickness of spacer washers (washer
thickness may vary slightly). Re-index marked spider leg
to another tower. This can be done because spider has
little effect on overall clutch balance.

(A)

(B)

SPIDER

JAM NUT

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

Re-indexing the spider 1/3 turn clockwise, or 1 leg, will
allow the realignment of the moveable and stationary
sheaves as previously marked (D). For EXAMPLE: 0.020"
or 0.032" (0.5 - 0.8mm) washer removed - re-index spider
clockwise 1/3 turn.

NOTE: Alignment marks on the sheaves should be
with in 1" (25.4mm) after final assembly and torquing.



When assembling a new clutch with all of the same
components, it is not uncommon for the marks not to
line up.

Drive Clutch Installation

NOTE: Always clean the clutch taper before re-
installing clutch on engine.

Place the specified clutch taper reamer in a vise and
lubricate the cutting edges with cutting oil. Clean the
clutch taper by manually rotating the clutch clockwise
on the reamer one or two revolutions. Only use the
weight of the clutch and do not push down on the
clutch while turning.

Check crankshaft taper for galling or scoring. If
necessary clean the taper evenly with 200 grit emery
cloth.

The clutch taper and the crankshaft taper should be
clean and dry. Do not use harsh cleaners which may
cause clutch taper to corrode, or damage the crank
seal.

Clean clutch taper with lacquer thinner or isopropyl
alcohol.

Slide clutch onto crankshaft taper.

Install the retaining bolt with all spacers and washers
or o-rings that were on the bolt when it was removed.

Hold the clutch with the holding wrench PN 931417-A.

Torque bolt to specification.

Run engine then re-torque the retaining bolt to
specification.

DRIVEN CLUTCH

Driven Clutch Removal

Remove the drive belt.

Apply and lock the parking brake.

Remove the driven clutch bolt and washers (A).

NOTE: Count the number and location of the spacer
washers located on the fastener and behind the
clutch.

Slide the driven clutch off the jackshaft.

Inspect the splines and replace jackshaft if damage is
found.

Driven Clutch Installation

Install the driven clutch bolt with the same amount of
washers at removal.

Torque the bolt to specification.

Check for correct belt deflection, and the clutch floats
on the shaft.

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