Polaris 600 RUSH 2010 Manual page 133

Disassembly / Assembly Process
1. Remove the coolant from the engine using a siphon,
wet/dry vac, or drain pan.
2. Remove the oil tank/clutch cover, air box assembly,
and exhaust pipe from the engine compartment.
3. Remove the high tension wires and spark plugs from
the cylinder head.
4. Remove the thermostat housing outlet cooling hose
from the housing.
5. Loosen all, then remove all head cover fasteners.
Clean the fastener threads to remove any thread
locking residue.
6. Discard the head cover and cylinder head o-rings.
Always use new o-rings during assembly.
7. Inspect the cylinder head / combustion domes for any
damage. Measure cylinder head flatness. Replace
cylinder head if required.
8. If only the cylinder(s) are going to be removed,
remove the fuel rail from the upper fuel injectors.
9. Loosen all, then remove the cylinder base nuts.
10. Carefully pull each cylinder upwards taking care not
to drop the piston and rod abruptly against the
crankcase.
11. Remove the cylinder base gaskets. Use a gasket
scraper to clean the gasket residue from the
crankcase and cylinder bases.
12. Inspect the cylinder walls. Nicasil cylinders can only
be lightly honed. Damage that cannot be removed
with a light hone requires cylinder replacement or re-
chroming.
13. The assembly process is the reverse of disassembly.
14. Always use new gaskets and o-rings during
assembly. Liberally coat the inside of each cylinder
and the outside of each piston with Polaris two-stroke
engine oil.
15. Always refresh the cylinder crosshatch pattern using
a 320 grit stone. See "Cylinder Honing" on page 3.14.
16. When installing a piston into a cylinder, verify each
piston ring opening is located at each piston ring
locating pin. Squeeze the top ring, then carefully slide
the cylinder over the compressed ring. Do the same
with the bottom ring.
17. Follow the torque
sequences located at beginning of chapter when
tightening fasteners.
specifications and torque
Engine/Cooling/Exhaust
3
3.23