Snowmobile Polaris (2006 year). Manual - part 29

6.2

ENGINE

GENERAL ENGINE 
INFORMATION

EXHAUST VALVE REMOVAL

1.

Remove the exhaust pipe.

2.

Remove the fasteners and hardware that hold on the
exhaust valve cap.

3.

Remove the cap.

4.

Fold the bellows up and remove the spring (1) and bellows
nut (2) from the guillotine. 

5.

Remove the bellows and the washer that is located under
the bellows.

6.

Remove the four fasteners (3) holding on the exhaust
valve base.

7.

Remove the base and base gasket.

8.

Remove the exhaust valve guillotine (4).

9.

Clean base and the guillotine with carbon clean.

WARNING

Exhaust system temperatures can exceed 900_F 

(500_C). Serious burns may occur of this inspection is 

performed without allowing adequate time for the ex-

haust system to cool. Never perform this procedure 

with the engine running.

CAUTION

Exhaust valve cover is under spring pressure. Hold 

the cover in place until all bolts are removed

2

1

3

3

4

6.3

ENGINE

10. Remove any gasket material from the base mating surface

on the cylinder.

EXHAUST VALVE INSTALLATION

1.

Place a new gasket on the valve base.

2.

Place the guillotine in to the cylinder.

IMPORTANT: The guillotine is orientated into the 
cylinder so that the larger shoulder (5) is located at 
the bottom and matches the cylinder area.

3.

Install the base so that the solenoid vent line is facing
upward

4.

Insert the base bolts and torque to 144 in-lb (16Nm).

5.

Place the solenoid vent line onto the base.

6.

Place the bellows washer (6) onto the guillotine shaft.

7.

Apply Loctite 242 to the threads of the guillotine shaft (7)
and torque the bellows nut to 144in-lb (16Nm).

8.

Insert spring (8) onto the bellows nut (9).

9.

Place cover and hardware on to the base and torque the

fasteners to 108 in-lb (12Nm).

REED VALVE DISASSEMBLY

NOTE:  Reeds should be cleaned if belt failure 
occurs or if plenum damage is present after a belt 
failure.

1.

Remove the carburetors or the throttle body. Throttle body,
See “THROTTLE BODY REMOVAL” on page 5.6

2.

Remove the intake boot fasteners (1).

3.

Remove the throttle body adapters (2).

4.

Remove the reed stuffer if they are used.

5.

Remove the reeds (3).

NOTE:  Measure the air gap between the fiber reed 
and the reed block. The air gap should not 
exceed.015"(.38mm). If clearance is excessive DO 
NOT attempt to reverse the reeds to reduce the air 
gap. Always replace them if damaged or worn. 
Check each fiber reed for white stress marks or 
missing material.

5

6

7

8

9

1

2

3

6.4

ENGINE

REED VALVE ASSEMBLY

1.

Place the reeds (3) and throttle body adapters (2) onto the
engine case.

2.

Torque the throttle body adapter fasteners (1) to 108 in-lb
(12Nm).

EXHAUST VALVE SPRINGS

THERMOSTAT REPLACEMENT

1.

Remove the thermostat cover, by removing the cover
bolts.

2.

Check the o-ring condition and replace it if it is cracked or
pinched.

3.

Replace the thermostat. Make sure that the spring side is
facing downward.

4.

Replace cover onto the thermostat and install the longer
cover fastener on the intake side of the engine. Place the
shorter fastener on the exhaust side of the cover.

5.

Torque the fasteners to 9 ft-lb (12Nm).

6.

Make sure that the bleed screw and washer is installed.

WATER TEMPERATURE SENSOR 
REPLACEMENT

1.

Remove the sensor.

2.

Replace the sensor and apply Loctite 242 to the threads
and torque to 30 ft-lb (40Nm).

Table 6-1: Exhaust Valve Springs

SPRING #

COLOR

FREE 

LENGTH

7041704-01

Blue

1.752

7041704-02

Orange

1.729

7041704-03

Pink

1.734

7041704-04

Purple

1.726

7041704-05

Yellow

1.734

7041704-06

White

1.537

600

1

2

3

4

5

6

7

700/900

6.5

ENGINE

700/900 ENGINE 

700/900 TORQUE SPECIFICATIONS

When tightening bolts, nuts, or screws, a torque pattern should 
be followed to ensure uniform equal tension is applied to all 
fasteners. Proper torque application prevents fasteners from 
loosening or breaking in critical service. It also minimizes 
wear and eliminates premature or needless repair costs. 
Following uniform torque application sequence patterns 
ensures optimum performance from precision machined, close 
tolerance assemblies.

The most common units of torque in the English system are ft-
lb (foot pounds) and in-lb (inch pounds). In the Metric system, 
torque is commonly expressed in units of Nm (Newton Meter).

1 =Apply Loctite 242 to threads of bolt.

2= Apply Pipe sealant to threads.

3= See torque sequence.

Table 6-2: 

ENGINE

700/900

SPARK PLUG

18 ft-lb (24Nm)

CYLINDER HEAD

27ft-lb (37Nm)1,3

BLEEDER SCREW

48 in-lb (4.5Nm)

THERMOSTAT HOUSING

108 in-lb (12Nm)

WATER TEMPERATURE SENSOR

216 in-lb (24Nm)2

WATER INLET PIPE

N/A

DETIONATION SENSOR

168 in-lb(19Nm)

CYLINDER BASE NUTS

40 ft-lb (54Nm)3

EXHAUST VALVE COVER BOLTS

 108 in-lb (12Nm)

EXHAUST VALVE NUT

 144 in-lb (16Nm)1

EXHAUST MANIFOLD BOLTS

22 ft-lb (30Nm)

CARB ADAPTER BOLTS

108 in-lb (12Nm)

OIL PUMP MOUNTING BOLTS

7 ft-lb (9Nm)

CRANCASE PLUGS

75 in-lb (8.5Nm)

WATER PUMP IMPELLER NUT

120 in-lb (14Nm)

WATER PUMP COVER BOLTS

108 in-lb (12Nm)

CRANKCASE 6mm

N/A

CRANKCASE 8mm

25ft-lb (34Nm)1,3

CRANKCASE 10mm

28 ft-lb (38Nm)1,3

ENGINE STRAP to CHASSIS NUT

22ft-lb (30Nm)

ENGINE STRAP to ENGINE BOLT

25ft-lb (34Nm)

STATOR BOLTS

144 in-lb (16Nm)1

TRIGGER COIL BOLTS

48 in-lb (5Nm)

FLYWHEEL

90ft-lb (122Nm)1

RECOIL CUP BOLTS

108 in-lb (12Nm)

RECOIL COVER COLTS

108 in-lb (12Nm)

DRIVE CLUTCH BOLT

96 ft-lb (130Nm)

7/16” ENGINE MOUNT STRAP BOLTS

N/A

REAR MOTOR MOUNTS BRACKET

29 ft-lb

(39Nm)

FRONT MOTOR MOUNT PLATE

22 ft-lb

(30Nm)