Chaincase Disassembly - Polaris 600 RUSH 2010 Manual

Chaincase Disassembly

1. Remove the left and right door panels. Remove the
screw securing the right lower fender to the chassis.
2. Remove the hood assembly.
3. Remove the exhaust silencer.
4. If equipped with electric start, remove the battery and
battery box.
CAUTION
Remove the BLACK (-) battery cable first, and then the
RED (+) cable last. Reverse order when attaching
cables to battery.
5. Place a drain pan under the chaincase. Remove the
plug to drain the oil. Clean the plug threads. Verify the
o-ring is not damaged.
6. Reinstall plug and torque to specification.
Chaincase Drain Plug: 8-9.5 ft-lbs (8-13 Nm)
7. Apply the parking brake and then loosen the brake
disc mounting fastener.
8. Release the parking brake. Remove the brake caliper
mounting bolts. Tie the caliper to overstructure.
NOTE: DC-CFI-2 models with Phantom brake calipers
have washers in place of silencer bracket. Phantom
Lite models do not use washers or bracket.
SILENCER BRACKET
CAUTION
Do not allow the brake caliper to hang by the brake hose.
= T
BRAKE CALIPER
O-RING
Final Drive/Brake System
9. Remove the brake disc from the jackshaft. Reference
table for brake disc hardware.
/
YEAR
BRAKE DISC FASTENER HARDWARE
CALIPER TYPE
Fastener: 29 ft-lbs (40 Nm)
2010/ Flat Washer
Phantom 1-2 Float Washers
(Install QTY. to achieve .8mm Disc Float)
Fastener: 40 ft-lbs (54 Nm)
2011-Current/ Flat Washer
Phantom Wave Washer
1 Float Washer
2011-Current/ Fastener: 40 ft-lbs (54 Nm)
Phantom Lite Domed (Beveled) Washer (Dome facing out.)
See Table
10. Note the groove on the seal sleeve. Use a pair of flat
blade screwdrivers or soft-jawed pliers to carefully pry
the sleeve out of the cover.
11. Locate the o-ring on the end of the jackshaft inside the
cover. Use a pick and carefully remove the o-ring.
Inspect o-ring and discard if damaged or torn.
5
O-RING
5.7