Snowmobile Polaris (2006 year). Manual - part 34

6.22

ENGINE

500/600 HO ENGINE 
REBUILDING

500/600 LIBERTY ENGINE DISASSEMBLY

1.

Remove reed valve assembly 

2.

Remove the head bolts (1).

3.

Remove the head cover (3) and the rubber head seals (4).

4.

Remove the head (5) and cylinder o-rings (6).

5.

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

6.

Remove the cylinder nuts (7) and carefully remove the
cylinders (8) with a slight rocking motion.

7.

Remove the c-clips that hold the wrist pin into the piston
(9).

8.

Using the piston pin puller PN 2870386 remove the piston

pins, and the piston from the crankshaft (15).

9.

Remove the water pump cover.

10. Remove the water/oil pump assembly. ‘500/600

LIBERTY WATER/OIL PUMP CROSS SHAFT
DISASSEMBLY” on page 6.24.

11. If removing the engine mounting straps (these straps are

mounted to the engine and bulkhead) label the direction
and placement of each engine strap.

12. Remove the cylinder base gaskets (10) and replace if

damaged.

13. Turn over the crankcase and remove the bottom crankcase

1

2

3

4

5

6

7

8

9

10

11

12

13

15

16

18

14

14

22(29.8)

32(43.4)

22(29.8)

17

5(6.8)

6.23

ENGINE

bolts (17,18).

14. Turn the crankcase assembly back over and remove the top

of the crankcase (12). 

15. Remove the crankshaft, and refer to the General chapter

for general engine component inspections and
measurement procedures.

6.24

ENGINE

500/600 HO/600 LIBERTY TORQUE 
PATTERNS

500/600 ENGINE ASSEMBLY

1.

Assemble the oil/water pump cross shaft as outlined on
‘500/600 LIBERTY WATER/OIL PUMP CROSS
SHAFT ASSEMBLY” on page 6.25.

2.

Set the crankshaft (15) with bearings and seals (14) into
the lower crankcase (16).

3.

If replacing the crankcase see the NOTE below.

NOTE:  If you are replacing the small block 
crankcase, ‘600 LIBERTY CYLINDER STUD 
INSTALLATION” on page 6.25.

4.

Fill the cross shaft section with cross shaft break in lube
PN 2872435.

5.

Place the top crankcase (12) on top of the lower crankcase
and crankshaft assembly.

6.

Apply Loctite 242 to the threads of the crankcase bolts
(16).

7.

Assemble the crankcase bolts into the crankcases. Torque
the bolts to 22 ft-lb(30Nm) in the case pattern shown in the
left column.

8.

Lubricate the small end bearings (13) and the piston pins
with Polaris 2 stroke oil and install the piston onto the
crankshaft with the piston pin removal/installation tool PN
2870386. 

9.

Install new c-clips in the piston grooves with the gap
facing straight up (12:00 position) or straight down (6:00
position). Make sure that the c-clip is fully seated in the
piston groove. Use c-clip installation tool PN 2872622.

10. Install the piston rings onto the piston with the bevel side

up and the gap facing the piston ring locating pin.

11. Install the base gaskets (10) on the upper crankcase.

12. Lubricate the cylinders and pistons with Polaris 2-stroke

oil and carefully install the cylinder onto the pistons by
squeezing the piston rings onto the locating pins and
rocking the cylinder gently from the intake and exhaust
sides.

13. Install the cylinder base nuts (7) and torque to 32 ft-

lb(43.4Nm) in the Cylinder Base pattern shown in the left
column.

14. Install o-rings (6).

15. Install the cylinder head (3) onto the cylinders.

16. Install head cover o-rings (4) with the head cover (3) on

the head.

17. Apply Loctite 242 on head bolt threads (1) and torque to

22ft-lb (29Nm).

18. Install VES. ‘EXHAUST VALVE INSTALLATION” on

page 6.3.

500/600 LIBERTY WATER/OIL PUMP 
CROSS SHAFT DISASSEMBLY

NOTE:  Inspect all parts for wear or damage during 
disassembly. Replace all seals, o-rings, and gaskets 

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

14

13

Head Pattern

Case Pattern

22 ft-lb (29.8Nm)

10mm 22ft-lb (29.8Nm)

7

3

5

1

2

6

4

8

Cylinder Base Pattern

32 ft-lb (43.4Nm)

MAG

PTO

PTO

MAG

6.25

ENGINE

with Genuine Pure Polaris parts during assembly. 
Refer General chapter for general inspection 
procedures.

1.

Remove the and disassemble engine 

2.

Remove the oil pump (1) and gasket (2).

3.

Carefully pull out the brass bushing (3) and o-ring (4).

4.

With the crankshaft installed, remove the impeller nut (5)
and washer (6). 

5.

Remove the impeller (7) and flat washer (8).

6.

Remove the cross shaft (9) by hitting the shaft from the
waterpower side with a rubber hammer.

7.

Press out the water pump shaft (10) out toward the oil
pump side.

8.

Remove the mechanical water pump seal (11).

9.

Pry out the seal (12) that is behind the mechanical seal. 

10. Remove the thrust washers from the shaft (13).

500/600 LIBERTY WATER/OIL PUMP CROSS 
SHAFT ASSEMBLY

1.

Install the seal (8) into the case.

2.

Insert the cross shaft (6) with the thrust washers (5,7) into
the case from the intake side.

3.

Install the flanged pump bearing (3) with the o-ring (4) on
to the cross shaft.

4.

Install the water pump mechanical seal (9). Use water
pump seal installation tool PN 2872010 and press it into
the case. Make sure that the sealant on the seal is facing
toward the crankcase.

5.

Install oil pump (1) with the gasket (2) onto the crankcase
and torque the bolts to 84 in-lb (31Nm).

6.

Place the flat washer (10), impeller (11), washer (12) and
impeller nut (13) onto the other side of the cross shaft.

7.

Torque the impeller nut (13) to 120 in-lb (44Nm).

600 LIBERTY CYLINDER STUD 
INSTALLATION

If you are replacing the small block crankcase, the new case 
will come with the studs loose, you will need to assemble the 
cylinder studs to a determined length.

You will need to thread in the Dri-Lok treated portion of the 
stud into the case. After stud assembly remove the Dri-Lok 
residue from the case assembly before assembly.

1

2

3

4

5

6

7

8

9

10

11

12 13

120(13.6)

Sealant

Case side

Cover side