Polaris 600 RUSH 2010 User Manual

5.26
Final Drive/Brake System
Phantom Brake Caliper Removal
1. Remove the two caliper bolts that hold the caliper and
silencer bracket to the chaincase.
NOTE: DC-CFI-2 models with Phantom calipers do
not
feature silencer bracket. Washers are installed in
its place.
2. Remove the caliper from the chaincase. Tie the
ca
liper to the overstructure. Do not allow the brake
caliper to hang from the brake hose.
Phantom Brake Caliper Installation
1. Apply Loctite® 242™ and replace caliper bolts, and
silencer bracket or washers if equipped. Torque bolts
to specification.
2. Place the brake line on the caliper in the same
orie
ntation as it was before it was removed.
3. Clean the threads of the banjo bolt and the threads in
the c
aliper.
4. Follow Brake Line Replacement. See “Brake Line
Replacement” on page 5.24.
5. Install banjo bolt into the caliper and torque it to
s
pecification.
6. Bleed the brakes. See “Brake Fluid Replacement &
Bleeding” on page 5.22.
7. Test brake system prior to returning vehicle to service.
Phantom Brake Caliper Piston and Seal
Replacement
1. Remove the brake hose from the caliper. Drain the
brake fluid into a jar or suitable container.
2. Rotate and remove the brake pad retaining pin and
th
en remove the brake pads. Remove the caliper from
the chaincase.
3. Hold the caliper over the brake fluid jar and then push
the pistons
back into the caliper. This will push the
brake fluid in the caliper out of the brake hose banjo
fitting hole.
4. Clamp the end of a 1/4” thick 2” x 10” piece of steel to
th
e workbench. Allow the piece of steel to hang off of
the bench by 4 - 5”.
= T
Caliper Bolts: 40 ft-lbs (54 Nm)
SILENCER BRACKET
600 RUSH DC-CFI-4 MODELS ONLY
ALL OTHER PHANTOM=WASHERS
CAUTION
NEVER RE-USE PISTON SEALS. ALWAYS REPLACE
WITH NEW PARTS.
DO NOT ATTEMPT TO SAND OR POLISH A CALIPER
PISTON.
CAUTION
NEVER RE-USE BRAKE FLUID. USED BRAKE FLUID
MAY CONTAIN AIR BUBBLES. ALWAYS USE NEW
BRAKE FLUID FROM AN UNOPENED CONTAINER.
PISTONS
PISTON SEAL
PISTON SEAL
CALIPER BORE PLUG
DO NOT PUSH OR MOVE!

Polaris 600 RUSH 2010 Specifications

General

Horsepower	120 HP
Engine Displacement	599 cc
Cylinders	2
Cooling	Liquid
Bore x Stroke	77.25 mm x 64 mm
Fuel System	Cleanfire Injection
Ignition	Digital CDI
Front Suspension	PRO-RIDE
Rear Suspension	PRO-RIDE
Track Width	15 in
Track Lug Height	1.25 in
Front Travel	9 in
Ski Stance	42.5 in
Brake	Hydraulic Disc
Width	48 in
Starter	Electric
Drive Clutch	P-85
Track Length	121 in
Rear Travel	14 in
Ski Type	Gripper
Driven Clutch	TEAM