Bonded Component Service; Overview; Bonded Component Removal; Bonded Component Surface Preparation - Polaris 600 RUSH 2010 Manual

BONDED COMPONENT SERVICE

Overview

The following serviceable components are bonded with
structural adhesive:
• Left/right bulkhead clips are bonded to the left/right
support braces
• Left/right support braces are bonded to the tunnel
assembly
• Bulkhead floor plate
• Top of front tunnel bulkhead cooler
NOTE: The left and right bulkhead clips are not
bonded to each other.
Please read and understand the topics outlined on the
following pages before working with any bonded
component.

Bonded Component Removal

Breaking the adhesive bond between the before-
mentioned components is required whenever performing
the following repairs:
• Left or right bulkhead clip removal/replacement
• Left or right engine support side brace removal/
replacement
• Front tunnel cooler removal/replacement
In every repair procedure listed, the bulkhead floor plate
must be removed. Breaking the bulkhead floor plate bond
will render the part unusable. The bulkhead floor plate is
considered a sacrificial part and will always be replaced
with a new plate whenever removed.
There are two removal methods. The first method does not
require the use of the direct application of heat to break the
bond. This method only involves removing the bulkhead
floor plate and front tunnel bulkhead cooler. This method
works because the adhesive has very little resistance to
peel force and therefore the two parts can be easily pried/
peeled off of the chassis.
The second removal method requires the use of the direct
application of heat to release the bond. This method of
removal only involves the removal of the bulkhead clip(s)
and/or engine support brace(s).
The recommended source of heat is the use of propane
gas, and can be obtained at most commercial hardware
stores.
NOTE: In all bonded component repair procedures,
the engine assembly and bulkhead floor plate are
removed from the engine compartment.

Bonded Component Surface Preparation

WARNING
Handling Practices
Ventilation - Work in a well-ventilated area.
Respirator - Use properly-fitted, organic vapor, air
purifying respirator (face mask).
Skin Protection - Use neoprene, or rubber gloves. Wash
hands and exposed skin with soap and water after
working with product.
Eye Protection - Wear safety glasses/goggles.
CAUTION
Original adhesive must be removed from bonded
components prior to the application of new adhesive.
Bonded components that will be re-used during assembly
must be cleaned and free from original adhesive.
Remove adhesive using a putty knife, gasket remover
tool, wire brush, etc. and propane gas torch.
Apply heat to adhesive to assist in removal. After all of the
residual adhesive is removed, the component mating
surface should resemble the example in the photo below.
After removing the adhesive, clean the bonding area with
warm, soapy water and allow to dry completely.
NOTE: New bonded parts should be washed with
warm, soapy water and allowed to dry completely
before the adhesive is applied.
Chassis
9
9.25