Snowmobile Polaris Two Stroke (2007 year). Manual - part 31

5.17

ENGINE

5

Assembly

1.

Grease oil pump drive gear area. Seals should be installed
with spring and lip facing inward toward crankshaft.

2.

Turn bearing until anti-rotation pins are positioned in the
proper location.

3.

Apply 3-Bond sealant to crankcase halves.

4.

Torque crankcase bolts following sequence outlined in
beginning of this chapter. Lubricate crankshaft main
bearings through access holes. Torque 8mm Bolts to 17-18
f.-lb (22-23 N-m), and 10mm bolts to 23-25 ft-lb
(32-35 N-m).

5.

Install pistons arrow toward flywheel.

6.

Install C-clip using installation tool PN 2870773.

7.

Install new base gasket. Mount gasket with the white
sealing material facing up.

8.

Lubricate rings and pistons with two stroke oil. Install rings
with letter, mark, or beveled side facing upward.

9.

Lubricate rings and cylinder with Premium 2 Cycle
Lubricant and compress rings with fingers, aligning end
gaps with locating pins. Install cylinder with a gentle front-
to-back rocking motion, being careful not to damage rings.

10. Install cylinder base nuts in pattern and torque to

27-31 ft-lb (37-43 N-m).

11. Install head gasket. Note proper position of gasket, “UP”

facing upward, small intake hole on right (mag) side, large
hole on left (PTO) side.

= T 

8mm Bolts to 17-18ft.lb. (23-25 N-m)

10mm Bolts 23-25 ft.lb. (32-35 N-m)

9

5

1

12

8

4

3

2

6

10

11

7

CRANKCASE PATTERN

= T 

Cylinder Base Nuts 27-31 ft.lb. (37-43 N-m)

7

1

3

5

4

2

6

CYLINDER BASE

5.18

ENGINE

12. Install cylinder head and torque cylinder head nuts to 18 -

19.5 ft-lb (25-27 N-m) following the torque pattern.

13. Before installing oil pump drive gear, refer to Oil Pump end

play adjustment.

14. Install oil pump drive gear in the sequence shown in

diagram below.

15. Install oil pump.

16. Connect oil feed lines to the cylinders.

17. Align stator as previously marked on stator plate and secure

with screws.

18. Install flywheel and torque flywheel nut to 60-65 ft-lb (83-

95 N-m) using the flywheel holding tool PN 8700229. 

19. Install water pump and recoil starter cup. make sure that the

thicker end of the drive pulley is towards the flywheel.

NOTE:  Belt deflection should be 1/8" - 3/16" (3-5mm)

20. Adjust tension on water pump belt by loosening water

pump mounting bolts, applying tension, and re-tightening
bolts.

21. Install recoil housing and carburetors.

22. Assemble and install oil pump onto engine.

23. Hook up the oil lines.

24. Bleed the oil pump.

25. Connect CDI to stator plug connector.

26. Pre-mix (32:1) the first tank of fuel. 

1

2

3

4

5

6

7

9

8

10

11

12

13

14

CYLINDER HEAD TORQUE PATTERN

Gear

Spacer

Bushing

Spacers

o-ring

Engine side

Oil Pump Side

5.19

ENGINE

5

500/600 HO ENGINE

Engine Removal

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

1.

Remove the side panels (if applicable).

2.

Disconnect battery ground (-) if applicable.

3.

Turn the fuel valve to the “OFF” position (1).

4.

Remove the exhaust system. 

5.

Disconnect the CDI box and harness from the air box.

6.

Pull up the air box and disconnect the vent lines and coil
connections.

7.

Remove the spark plug caps from the spark plugs.

8.

Remove the air box.

9.

Remove the recoil handle and secure the recoil rope (2).

10. Remove the drive belt, driven clutch and drive clutch. 

11. Squeeze the vent line clamps and remove the exhaust valve

vent lines from the top of the exhaust valve base.

12. Disconnect the DET sensor connection (4).

13. Remove the panduit strap and, disconnect the throttle

position sensor (TPS) from the carburetor.

14. Disconnect the Regulator Rectifier (5) and the Stator

connections (6). These are located behind the brake disc
area.

15. Loosen up the boot clamps that hold the carburetor onto the

intake.

16. Separate the carburetors from the engine.

17. Disconnect the oil supply lines from the carburetor and

secure the carburetor assembly out of the way.

NOTE:  Plug the carburetor areas to keep any debris
from entering the carburetors.

18. Drain the engine coolant.

NOTE: Disconnect the thermostat hose and place
the end into a container and use low air pressure
and coolant should come out of the hose.

19. Move the thermostat hose clamp down on the hose far

enough to clear the fitting on the head, and remove the hose.

1

2

4

5

6

5.20

ENGINE

20. Move the hose clamp (7) and remove and secure it out of

the way.

21. Remove the coolant supply hose that is located at the

bottom of the coolant bottle and secure it out of the way.
This will come out with the engine.

22. Remove the rear (9) and left (10) motor mount nuts located

on the right hand side of the engine. 

23. Remove the left hand rear torque stop fasteners (11)

24. Remove the inside motor mount fastener (12), located

under the PTO carburetor boot.

25. Remove the rear torque stop plate.

26. Remove the engine isolator limiter assembly fasteners (13)

and then remove the torque stop assembly.

27. Remove the LH front motor mount nylock nut (14) and

washer.

28. Remove the LH nose pan plug located on the nose pan next

to the shock tower. This will allow access to the front
fasteners for the LH chassis brace.

7

RH Rear

RH Front

9

10

11

12

13

14