Engine Installation - Polaris 600 RUSH 2010 Manual

Engine/Cooling/Exhaust

Engine Installation

1. Clean the engine compartment.
2. Inspect engine mounts for damage. Replace mounts
or radial inserts at this time. If any mount bracket was
removed, reinstall and torque screws to specification.
Engine Mount Bracket: 22 ft-lbs (30 Nm)
3. Verify cooling hose and starter motor power cable
(electric start models) are secured to the bulkhead
floor with a p-clamp.
NOTE: White tape on wire harnesses and hoses
designates clamp/harness retainer location.
4. Visually inspect the oil pump setting. If adjustment is
required, adjust the oil pump before installing the
engine.
5. With the help of an assistant of engine hoist, lower the
engine into the bulkhead.
6. Spray the radial inserts on each of the four engine
mounts with rubber lubricant or isopropyl alcohol.
Lubricating the radial inserts will prevent the engine
fasteners from catching on the rubber when they are
torqued.
7. Install all four engine mount screws by hand. Once all
four are installed, torque screws to specification.
Engine Mount Screws: See Page 3.20.
8. Install the torque link adjuster using a new lock nut.
Torque lock nut and screws to specification.
Torque Link Nut/Screws: 26 ft-lbs (35 Nm)
9. Reinstall the surge tank-to-water pump and heat
exchanger-to-water pump hoses on to the water
pump cover.
10. Reinstall the coolant outlet and bypass outlet hoses
at the thermostat housing. Open the bleed slightly to
allow air to escape when the engine is filled with
coolant.
11. If the snowmobile is equipped with electric start,
reinstall the starter worm drive shaft, and the starter
motor.
3.38
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12. Reinstall the exhaust gaskets and y-pipe. Torque y-
pipe fasteners to specification.
Exhaust Y-Pipe Screws: 22 ft-lbs (30 Nm)
13. Reinstall the throttle cable. Verify the throttle cable
freeplay is set to specification.
14. Install the MAG and PTO exhaust valve assemblies
using new gaskets. Torque fasteners to specification.
Reconnect vent hoses and secure clamps.
GASKET
Exhaust Valve Mounting Screws: 2 ft-lbs (16 Nm)
Apply Loctite® 242™
15. Reinstall the lower steering shaft bushing bracket on
to the over structure by loosely installing the two
screws. Torque fasteners to specification.
Lower Steering Shaft Bushing Bracket:
15 ft-lbs (20 Nm)
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FASTENERS
EV ASSEMBLY
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