800 Dc-Cfi-2 Crankshaft Identification - Polaris 600 RUSH 2010 Manual

Disassembly and Assembly Process - Crankcase/
Crankshaft
1. Remove the engine from the engine compartment.
2. Follow the process for removing the cylinder head,
cylinders, pistons, flywheel/recoil housing, and the
water/oil pump.
NOTE: The crankcase ring land damage shown in the
corresponding photo
crankcase separation or crankshaft removal.
3. Remove all crankcase fasteners except ones marked
5-6-7-8 indicated below. Loosen these 4 bolts to
reveal about a 1/6"-1/8" bolt gap.
4. Once loosened, carefully and lightly tap on the bolts
to separate the crankcase halves.
5. Discard the PTO and MAG crankshaft seals.
6. Remove the crankshaft by pulling it straight up and
out. Inspect as required.
7. Thoroughly clean the two crankcase mating surfaces
with carburetor cleaner and a gasket remover. Flush
out the crankcase galleries.
8. Reinstall the crankshaft back into the lower crankcase
using two new crankcase seals.
9. Apply a thin bead of Three Bond 1217H to the lower
crankcase mating
crankcase.
is caused by improper
surface. Install the upper
Engine/Cooling/Exhaust
NOTE: Do not over-apply sealant in oil injector area.
Doing so may block the oil passage.
10. Loosely install the crankcase fasteners, then torque to
the specifications at the beginning of the chapter. Use
the correct torque sequence when tightening the
screws.
11. Liberally coat the
components with Polaris two-stroke engine oil.

800 DC-CFI-2 Crankshaft Identification

Two different crankshaft assemblies (Type 1 and Type 2)
are used for production and service parts. Use the codes
etched into the nose of the PTO end to determine
crankshaft type when ordering service parts.
Type 1 will have the number 3753. Type 2 will have the
number 0262.
DOWELS
DO NOT FILL MAG
BEARING OIL
GALLERY WITH
CASE SEALANT
crankshaft bearings and
3.31
3