Snowmobile Polaris (2006 year). Manual - part 31

6.10

ENGINE

35. Install a cable strap (9) around the coolant lines and the

wiring harness at the relay area of the wiring harness and
at the shock tower area.

36. Install the left hand brace onto the left side of the bulkhead

in the same manner as the right side.

37. Hook up the fuel filter. 

38. Install the fuel filter bracket

NOTE:  The fuel filter and holder are located on the 
top rear faster on the brace.

39. Torque all fasteners to 12 ft-lb (16Nm).

40. Install the fender plug.

41. Check engine torque stop and adjust if needed. ‘TORQUE

STOP” on page 3.24

42. Install exhaust gaskets and header. Torque the header

fasteners to 22 ft-lb (30Nm).

43. Install the boost box to the throttle body.

44. Tighten the boot clamps.

45. Hook up the intake air sensor.

46. Install the fuel tank, and seat. ‘SEAT and FUEL TANK”

on page 12.4

47. Install the console. ‘IQ CONSOLE REMOVAL /

INSTALLATION” on page 12.6

48. Route recoil rope through the chassis and install recoil

handle.

49. Install the clutches and belt. ‘DRIVE CLUTCH

INSTALLATION” on page 7.19 or ‘DRIVEN CLUTCH
INSTALLATION” on page 7.20 ‘BELT
INSTALLATION (Team Driven Clutch)” on page 7.5

50. Install the exhaust system. ‘EXHAUST

INSTALLATION” on page 3.16

51. Hook up plug wires to spark plugs. Plug wires are labeled.

52. Install the plenum. ‘IQ 700/900 AIR INTAKE

INSTALLATION” on page 12.7

53. Install side panels.

9

6.11

ENGINE

700/900 ENGINE REBUILDING

700/900 DISASSEMBLY

1.

Remove the recoil housing and stator. See “700/900
RECOIL/STATOR DISASSEMBLY” on page 6.14

2.

Remove the fuel rail. See “FUEL RAIL/INJECTOR
REMOVAL” on page 5.3

3.

Remove the throttle body. See “THROTTLE BODY
REMOVAL” on page 5.6

4.

Remove the reeds. See “REED VALVE
DISASSEMBLY” on page 6.3

5.

Remove the exhaust valve assembly. ‘EXHAUST
VALVE REMOVAL” on page 6.2

6.

Remove the head bolts (1).

7.

Remove the head (2) and o-rings (3).

8.

Remove the cylinder bolts (4).

9.

Remove the cylinders (5).

10. Remove the MAG side piston c-clips from the pistons.

11. Remove the piston pins using the piston pin removal/

installation tool (PN 2870386).

12. Remove the pistons (6) and pin bearings from the

crankshaft.

13. Remove the base gaskets (7).

14. Account for all the cylinder locating pins (8).

15. Remove the oil pump and all oil lines from the crankcases.

16. Flip the engine over and remove the loser case bolts (14).

17. Separate the upper and lower cases (9,13).

18. Remove the crankshaft assembly (11) from the lower case.

1

22(29)

2

3

4

5

14

13

12

11

10

12

9

8

7

6

23(31)

6.12

ENGINE

19. Refer to the General section form general engine

component inspections and measurement procedures.

700/900 TORQUE PATTERNS

700/900 ASSEMBLY

1.

Lubricate all the crankshaft seals (12) with Polaris All
Season grease. Make sure that the seals are positioned
properly with the lip and spring facing inward toward the
center off the crankshaft.

2.

Instal the crankshaft assembly in the lower crankcase.

3.

Fill in the cross shaft area with engine assembly lubricant
(PN 2872435).

4.

Apply a thin bead of 3 Bond 1215 sealant (PN 2871557)
to the lower case (13) matting surface.

5.

Assemble the upper case (9) to the lower case (13),
making sure that the seals and bearings fit in the locations
on the upper case half.

6.

Follow the crankcase bolt torque pattern and torque the
lower case bolts to 23 ft-lb (31Nm).

7.

Lubricate the piston pin bearings and the piston pins with
Polaris 2 stroke oil and install the piston onto the
crankshaft with the piston pin removal/installation tool.

8.

Install new c-clips in the piston grooves with the gap
facing correctly, (MAG c-clip in the 10:00 position) or
(PTO c-clip in the 2:00 position). Make sure that the c-clip
is fully seated in the piston groove.

9.

Install the piston rings onto the piston with the bevel side
up and the gap facing the piston ring locating pin.

10. If old base gaskets are damaged, install new ones. 

NOTE:  New base gaskets have a rib that faces 
upward.

11. Lubricate the cylinders and pistons with Polaris 2 stroke

oil and install the cylinders onto the pistons by squeezing
the piston rings onto the locating pins in the piston ring
groove, rock the cylinder gently back and forth until the
cylinder can be installed onto the upper case matting
surface.

12. Install the cylinder base bolts and torque to 34 ft-lb

(46Nm) in the sequence found on page 6.12.

13. Install new head o-rings if the old ones are damaged.

14. Install the head onto the cylinders.

15. Torque the head bolts to 22 ft-lb (29Nm) in the sequence

found on page 6.12

16. Install water pump cover.

17. Install the reeds. See “REED VALVE ASSEMBLY” on

page 6.4

18. Install the fuel rail. See “FUEL RAIL/INJECTOR

REMOVAL” on page 5.3

19. Assemble the recoil/stator. See “700/900 RECOIL/

STATOR ASSEMBLY” on page 6.14

20. Install the front motor mount, and torque the fasteners to

25 ft-lb (34Nm).

700/900 WATER/OIL PUMP CROSS SHAFT 
DISASSEMBLY

1.

Remove the water pump cover bolts (1)

1

2

3

4

5

6

7

8

9

10

MAG

PTO

12

11

11

9

7

5

1

3

2

4

6

8

12

10

Head Pattern

Case Pattern

22 ft-lb (29.8Nm)

8mm 22ft-lb (29.8Nm)

14

16

15

13

7

3

5

1

2

6

4

8

Cylinder Pattern

40 ft-lb (54.2Nm)

MAG

PTO

PTO

MAG

6.13

ENGINE

2.

Remove the water pump cover (2) and gasket (3).

3.

Remove the impeller nut and washer.

4.

Remove the impeller.

5.

With two flat head screw drivers pry the water pump seal
out by lifting up on the seal flange. This will crush the
flange upward.

6.

Pry the mechanical seal out of the case.

NOTE:  You will destroy the oil seal when you 
remove it from the case. You will also mar up the 
case while you are removing the mechanical seal. 
This seal can not be reused.

7.

Remove the oil seal by screwing in a screw into the oil seal
and pulling it out of the case.

1

2

3