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Snowmobile Polaris (2006 year). Manual - part 35

6.26

ENGINE

The long studs are installed to a height of 3.66" (93mm). The
small studs are installed to a height of 2.16" (55mm).

500/600 RECOIL/STATOR REMOVAL

Remove the recoil cover (2).

Remove the recoil basket bolts (1) and the recoil basket
(4).

Using a strap wrench PN PU-45419 hold the flywheel
while taking the flywheel nut (5) and washer (6) off.

Using the Flywheel Puller PN 2871043, thread the puller
bolts into the flywheel. Do not install puller bolts more
than 5/16, (7mm) into flywheel threads or stator damage
may result.

Tighten the center bolt and remove the flywheel (7).

Note the ignition timing marks that match up with the
stator to the crankcase or scribe additional marks for
reference for assembly.

Remove the stator bolts (8), and remove the stator (9). Be
careful when removing the wires of the stator.

500/600 RECOIL/STATOR ASSEMBLY

NOTE: Inspect all parts for wear or damage during
disassembly. Replace all seals, o-rings, and gaskets
with Genuine Pure Polaris parts during assembly.
Refer General chapter for general inspection
procedures.

Install the stator (9) and align the timing marks that was
noted earlier.

Apply Loctite 242 to the first few threads of the stator
bolts (8) and torque to 5 ft-lb (7Nm).

Install the flywheel (7) so that it matches up with the index
of the woodruff key.

Apply Loctite 242 to the threads of the flywheel nut (5)
and place the washer (6) and nut onto the end of the
crankshaft.

Holding the flywheel with the strap wrench, torque the
flywheel nut to 90 ft-lb (122Nm).

Install the recoil basket (4) and the recoil basket bolts (3)
on the flywheel and torque the bolts to 9 ft-lb (12Nm).

Install recoil assembly (2) and torque the recoil assembly
bolts (1) to 9 ft-lb (12Nm).

340/550 FUJI ENGINE/500
LIBERTY

340/550 FUJI/500 LIBERTY ENGINE
REMOVAL/INSTALLATION

Turn the fuel valve to the “OFF” position.

Remove the exhaust system.

Disconnect the battery ground (-) if applicable.

Disconnect the CDI box.

Remove the spark plug leads form the spark plugs.

Disconnect the stator connection(s).

Remove the air box.

Remove the drive belt.

Remove the drive and driven clutches.

10. Remove the recoil handle and secure the rope so that it is

on the recoil housing.

11. Loosen the carburetor clamps that are holding the

carburetor onto the boots.

12. Separate the carburetors and secure them out of the way

for engine removal.

13. Disconnect the oil pump cable from the oil pump.

14. Disconnect the oil supply line at the oil pump, and plug the

end with a clean bolt.

15. Remove the fuel pump impulse line from the engine.

16. Remove all the motor mount nuts.

17. Remove the engine.

18. Install in reverse order.

9(12)

90(122)

5(7)

6.27

ENGINE

340/550 ENGINE REBUILDING

6.28

ENGINE

340/550 ENGINE DISASSEMBLY

NOTE: Inspect all parts for wear or damage during
disassembly. Replace all seals, o-rings, and gaskets
with Genuine Pure Polaris parts during assembly.
Refer to the ‘INSPECTONS” on page 3.5 for general
inspection procedures.

Disconnect the coil pack from the recoil cover and the
wiring harness.

Loosen the carburetor clamps (1) and remove the
carburetors from the mounting boots.

Note where the oil lines are routed and remove the oil lines
from the carburetors.

Remove the carburetor mounting boots (2) from the
cylinders.

Remove both the cylinder head (3) and the exhaust side
fan (4) shrouds from the engine assembly.

After removing the fan shrouds, take note of the vibration
dampener (5) located between the cylinders month intake
side.

Remove the CDI from the flywheel cover.

Remove the flywheel cover (6).

Remove the recoil cup (7).

10. Hold the flywheel with the holding wrench PN 8700229

and remove the flywheel nut and washer.

11. Using a flywheel puller (PN 2871043), remove the

flywheel (8) from the engine. Do not install the puller bolts
in amy more than 5/16” of an inch/7.9mm into the
flywheel threads or stator damage may result.

12. Remove the flywheel and woodruff key.

13. Remove the stator plate.

14. Remove the oil pump (9). Note the o-ring and shim

placement.

15. Remove the cylinder head bolts (10).

16. Remove the cylinder head (11).

17. Remove the head gasket (12). During the removal process

note that the gasket has a EX for exhaust side and UP for
the orientation.

18. Remove the cylinder base nuts (13) and carefully remove

each cylinder.

19. Remove the reed valve assembly (14) from the crankcase.

20. Remove the wrist pin c-clips

21. Using a piston pin puller (PN 2870386) remove the wrist

pins from the pistons.

22. Turn the crankcase over and remove the crankcase bolts

(15).

23. Carefully turn the case back over and separate the case

halves.

24. Remove the crankcase seals (16).

25. Remove the oil pump bushing, spacer, and cross shaft (17)

and inspect for any wear or damage.

340/550 ENGINE ASSEMBLY

Insert the oil pump cross shaft, spacer and bushing.

Install a new o-ring on the oil pump.

Place the oil pump aside for later installation.

Set the crankshaft into the lower case half.

NOTE: Make sure that the crankshaft rotates
smoothly and does not bind. Rotate the bearings so
that the anti-rotation pins are testing in their
appropriate galleries.

Apply 3-Bond (PN 2871557) sealer to the top half of the
crankcase.

Apply Polaris 2-Stroke engine oil to the oil pump cross
shaft in the lower half of the crankcase.

Install new crankcase oil seals.

Match up the top half of the crankcase to the lower case
and hold the case halves together and turn it upside down.

Install the crankcase bolts and torque to 18 ft-lb (25Nm).
in the pattern shown below.

10. Turn the crankcase over an install the pistons with the

arrow on the piston crown facing the flywheel (MAG)
side. This will orientate the piston so that the piston ring
locating pins will be in the intake side of the engine.

11. Apply Polaris 2-Stroke engine oil to the wrist pins and the

small end bearings and install them onto the crankshaft
with the piston installation tool (PN 2830386).

12. Lubricate rings and the pistons with Polaris 2-Stroke oil

and install the rings with the letter, mark or beveled side
facing upward.

13. Install the c-clips into the piston so that the opening of the

“C” is positioned at the 12:00 or 6:00 position.

14. Install the reed valves in to the intake of the crankcase.

15. Install new base gaskets.

16. Compress the piston rings and install each cylinder onto

the crankcase.

CRANKCASE TORQUE PATTERN-FUJI

6.29

ENGINE

17. Torque the cylinder base nuts to:

•340 = 17-18 ft-lb (23-25Nm)

•550 = 25-30 ft-lb (34-40Nm)

18. Install a new head gasket with the “EX” facing the exhaust

side. Also make sure that the “UP” is facing the intake side
of the engine.

19. Insert the head bolts and torque to:

•340 = 18-21 ft-lb (25-28 Nm)

•550 = 17-21 ft-lb (23-28 Nm)

20. Insert the dowels on the stator housing that match up with

the crankcase.

21. Route the stator wires harness correctly.

22. Install the flywheel, lock washer, woodruff key, and

flywheel nut onto the shaft.

23. Torque the flywheel nut to:

• 340 = 61-70 ft-lb (83-90Nm)

• 550 = 58-72 ft-lb (79-98Nm)

24. Install the recoil cup onto the flywheel.

25. Install the recoil cover.

26. Install the CDI box on the flywheel cover.

27. Insert the vibration dampener in between the cooling fins

that are located between the two cylinders on the intake
side.

28. Install the two fan deflectors.

NOTE: Make sure that the fan deflectors interlock
before tightening down.

29. Install the oil pump onto the lower case half.

NOTE: Install all oil pump shims.

30. Apply Blue Loctite 243 to the oil pump mounting screw

threads and torque to 48-72 in-lb (5.5-8.3Nm).

31. Route each oil line on the oil pump in the correct positions.

32. Install intake boots.

33. Install the boot clamps onto the boots.

34. Install the carburetors onto the boots.

35. Tighten the boot clamps.

36. Insert engine into the chassis.

500 FUJI

DISASSEMBLY

NOTE: Inspect all parts for wear or damage during
disassembly. Replace all seals, O-rings, and gaskets
with Genuine Polaris parts during assembly. Refer to
General Section for Inspection Procedures.

Remove carburetors, recoil housing and exhaust manifold.

Remove water pump, and starter recoil cup with water
pump drive pulley and flywheel nut.

Install flywheel puller PN 2871043. Use all flywheel bolt
holes. Do no install puller bolts more than 5/16, (7mm)
into flywheel or stator damage may result.

CYLINDER BASE TORQUE PATTERN-FUJI

CYLINDER HEAD TORQUE PATTERN-FUJI

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