Polaris 800 RUSH 2011 User Manual

3.38
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.
3. Verify cooling hose and starter motor power cable
(elec
tric start models) are secured to the bulkhead
floor with a p-clamp.
NOTE: White tape on wire harnesses and hoses
de
signates 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 assistan
t of engine hoist, lower the
engine into the bulkhead.
6. Spray the radial inserts on each of the four engine
mo
unts 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
fo
ur are installed, torque screws to specification.
8. Install the torque
link adjuster using a new lock nut.
Torque lock nut and screws to specification.
9. Reinstall the surge tank-to-water pump and heat
ex
changer-to-water pump hoses on to the water
pump cover.
10. Reinstall the coolant outlet and bypass outlet hoses
a
t 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,
r
einstall the starter worm drive shaft, and the starter
motor.
12. Reinstall the exhaust gaskets and y-pipe. Torque y-
pipe
fasteners to specification.
13. Reinstall the throttle cable. Verif
y the throttle cable
freeplay is set to specification.
14. Install the MAG and PTO exhaust valve assemblies
using ne
w gaskets. Torque fasteners to specification.
Reconnect vent hoses and secure clamps.
15. Reinstall the lower steering shaft bushing bracket on
to the
over structure by loosely installing the two
screws. Torque fasteners to specification.
= T
Engine Mount Bracket: 22 ft-lbs (30 Nm)
= T
Engine Mount Screws: See Page 3.20.
= T
Torque Link Nut/Screws: 26 ft-lbs (35 Nm)
= T
Exhaust Y-Pipe Screws: 22 ft-lbs (30 Nm)
= T
Exhaust Valve Mounting Screws: 2 ft-lbs (16 Nm)
Apply Loctite® 242™
= T
Lower Steering Shaft Bushing Bracket:
15 ft-lbs (20 Nm)
GASKET
EV ASSEMBLY
FASTENERS

Polaris 800 RUSH 2011 Specifications

General

Brand	Polaris
Model	800 RUSH 2011
Category	Snowmobiles
Language	English