Front Heat Exchanger Service - Polaris 600 RUSH 2010 Manual

Engine/Cooling/Exhaust

Front Heat Exchanger Service

1. Remove the left and right door panels. Remove the
hood assembly.
2. Remove the exhaust pipe.
3. Drill out and remove the rivets that attach the air dam
plate to the bulkhead, and the two rivets that attach
the nosepan to the plate.
4. Remove the screw attaching the bumper to the heat
exchanger. Loosen the two rear bumper screws.
REMOVE THIS SCREW
5. Drill out the rivets that attach the bumper to the
nosepan.
6. Rotate the bumper up and away from the nosepan.
7. Locate the lower exchanger fastener.
3.50
LOOSEN REAR SCREWS
AIR DAM PLATE
NOSE PAN
8. Remove the bottom heat exchanger fastener.
9. Pinch-off the coolant in and out hoses using dedicated
hose pinchers or soft-jawed pliers.
10. Remove the two heat exchanger hose clamps.
Remove the heat exchanger from the bulkhead.
11. Reverse the disassembly process to install the heat
exchanger and bumper.
12. Add engine coolant to the surge bottle. Bleed the
cooling system. See "Cooling System Bleeding" on
page 2.10.
BOTTOM FASTENER