Oil Tank/Clutch Cover Service - Polaris 600 RUSH 2010 Manual

Maintenance

Oil Tank/Clutch Cover Service

The oil tank is mounted to the clutch cover assembly. The
oil tank/clutch cover assembly can be removed from the
vehicle to access components within the engine
compartment.
NOTE: Because of the relative ease of removing both
the oil tank and clutch cover at the same time, both
processes have been combined although not all
service procedures will require the removal of the
clutch cover.
1. Open the engine compartment door panels, and
remove the hood.
2. Remove the hood assembly.
FILL CAP/ECU BRACKET
OIL LEVEL SENSOR
FILL CAP/ECU BRACKET
3. Disengage the rubber strap from the cover at the back
of the oil tank.
4. Remove the screw securing the bottom of the tank to
the clutch cover.
5. Remove cap. Remove the ECU bracket from the oil
tank. Reinstall the fill cap. Disconnect the oil level
sensor.
6. Disconnect the two wire harness connectors from the
ECU.
7. Disconnect the wire harness connections at the
regulator/rectifier, and capacitor. Release the wire
conduits from the rosebud connectors.
8. Remove the four nuts securing the clutch cover from
the chassis.
9. Carefully pull up and release the cover from the
mounting studs.
10. Using a needle nose pliers, slide the clamp back and
remove the oil supply hose at the filter location. Use
the pliers to pinch the supply hose to prevent oil loss.
2.14
MOUNT SCREW
RUBBER STRAP
11. Installation is the reverse of removal. After installing
the supply hose on to the filter and installing the
clamp, hold the oil tank high in the engine
compartment with the supply hose pointed down to
allow the trapped air to bleed upwards into the tank.
CAUTION
Verify the oil supply hose is not kinked after installing the
oil tank/oil supply hose.
12. Install the ECU bracket, and fill cap.
13. Torque the lower tank screw to specification. Install
the rubber strap.
Oil Tank Mount Screw
10 ft-lbs (12 Nm)
= T