Snowmobile Polaris Two Stroke (2007 year). Manual - part 35

5.33

ENGINE

5

600/700 CFI Engine Disassembly

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24

27

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31

32

29

25

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17

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8

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30

If new see

installation

height on

page 5.5

5.34

ENGINE

1.

Remove the spark plugs (1)

2.

Remove reed valve assembly. See “Reed Valve
Disassembly” on page 5.3.

3.

Remove the recoil and stator assembly. See “Recoil/Stator
Removal” on page 5.7.

4.

Remove the fuel rail. See “600/700 CFI Fuel Rail/
Injector(s) Removal/Installation” on page 4.17.

5.

Remove the head bolts (5).

6.

Remove the head cover (8) and the rubber head seals (9).

7.

Remove the head (11) and cylinder o-rings (13).

8.

Remove the VES assembly. See “Exhaust Valve
Disassembly” on page 5.3.

9.

Remove the cylinder nuts (14) and carefully remove the
cylinders (15) with a slight rocking motion.

10. Support one of the pistons with the piston support block PN

2870390.

11. Remove the c-clips that hold the wrist pin into the piston.

12. Using the piston pin puller PN 2870386 and adapter PN

2871445 remove the piston (wrist) pins, and the piston (16)
and small end bearings (22) from the crankshaft rod.

13. Remove the water/oil pump assembly. See “500/600/700

Water/Oil Pump Cross Shaft Disassembly” on page 5.6.

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

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

15. Remove the cylinder base gaskets (17) and replace them if

damaged.

16. Turn over the crankcase and remove the bottom crankcase

bolts (32).

17. Make sure that cylinder dowels (19) are accounted for.

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

of the crankcase (21). 

19. Remove the crankshaft assembly (24-28), and refer to the

General chapter for general engine component inspections
and measurement procedures

. 

See “INSPECTONS” on

page 3.5.

NOTE: If new cases are to be installed make sure
that the new cylinder studs are installed to the
correct length. See “Cylinder Stud Installation” on
page 5.5.

Engine Assembly

1.

Assemble the oil/water pump cross shaft as outlined on
See “500/600/700 Water/Oil Pump Cross Shaft
Assembly” on page 5.6.

2.

Set the crankshaft assembly (24-28) into the lower
crankcase (29).

3.

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

4.

Place the top crankcase (21) on top of the lower crankcase
(29) and crankshaft assembly. Make sure that seals (25, 28)
are lined up properly to each case section.

5.

Apply Loctite 242 to the threads of the lower crankcase
bolts (32).

6.

Assemble the crankcase bolts into the crankcases. Torque
the bolts to 22 ft.lb. (30 N-m). Torque in sequence. See
“600/700 CFI Crankcase Torque Pattern” on page 5.35.

7.

Lubricate the small end bearings (21) 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 and adapter PN 2871445. 

8.

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 2872622A.

9.

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

10. Install the base gaskets (17) on the upper crankcase.

11. 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.

12. Install the cylinder base nuts (14) and torque to 32 ft-lb

(43.4 N-m) in the Cylinder Base pattern. See “600/700 CFI
Cylinder Base” on page 5.35.

13. Install cylinder o-rings (13).

14. Install the head (11) onto the cylinders.

15. Install head cover o-rings (9) with the head cover (8) on the

head.

16. Apply Loctite 242 on bolt threads (5) and torque to 22ft-lb

(29 N-m). Torque in the pattern. See “600/700 CFI
Cylinder Head Torque Pattern” on page 5.35.

17. Install VES. See “Exhaust Valve Assembly” on page 5.3.

= T 

Head Bolt Torque 22 ft.lb. (30 N-m)

= T 

Cylinder base Nut Torque 32 ft.lb. (43 N-m)

= T 

Head Bolt Torque 22 ft.lb. (29 N-m)

5.35

ENGINE

5

600/700 CFI Cylinder Head Torque Pattern

600/700 CFI Cylinder Base

600/700 CFI Crankcase Torque Pattern

600/700 CFI Engine Installation

1.

Make sure that you have the engine assembled in the state
that it was when it was removed. This includes all the
coolant hoses, oil lines, and electrical wires.

2.

Fill oil lines with 2 stroke engine oil when assembling.

3.

Clean the oil residue and debris out of the engine
compartment.

4.

To assure a smooth transition of the loose engine into the
engine compartment, secure all loose hoses that are in side
the engine compartment.

NOTE: You may need a helper with the installation
of the throttle and oil cables.

5.

Place the engine on the shock tower brace and hold engine
at this point.

6.

With the throttle bodies separated from the intake adapters,
route the throttle cable behind the fuel rail and insert the
throttle cable into the throttle pulley located in the center
of the throttle bodies.

7.

Insert the throttle body into the adapters and tighten the
clamps in the orientation as shown below.

8.

Adjust the throttle cable adjuster nut so that you have the
correct throttle free play. See “Throttle Lever Free Play -
Non CFI” on page 3.18.

9.

Place the oil cable into the oil pump arm. The oil pump arm
has a slot (1) in the back to slide the cable through for
installation. The plastic end of the throttle cable is inserted
so that the large flat is facing the engine and the small end
is facing the out side.

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MAG

PTO

12

11

Head Pattern

25 ft-lb (34 N-m)

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3

5

1

2

6

4

8

Cylinder Base Pattern

32 ft-lb (43 N-m)

MAG

PTO

11

9

7

5

1

3

2

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8

12

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14

13

Case Pattern

22ft-lb (30 N-m)

PTO

MAG

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5.36

ENGINE

10. Using a 10mm open end wrench tighten the lock nut while

holding the other nut with a 10mm open end wrench. Make
sure that the oil cable angle is tilted slightly toward the
engine (2).

11. Thread on the adjuster nut and adjust the oil pump and

adjust the oil pump. See “Oil Pump Adjustment” on
page 3.19.

12. Carefully place the engine into the engine compartment and

line up the engine mount studs with the engine straps on the
engine. 

NOTE:  Make sure that all hoses, lines and wires are
not pinched or interfere with installation.

13. Route the oil supply line from the engine through the hose

guide.

14. Install the oil bottle and hook up the supply line (3). Open

and slide the hose clamp onto the hose and oil bottle fittings.

15. Secure the oil bottle to the chassis by installing the two torx

fasteners located at the top of the bottle (14).

16. Connect the oil sender (Yellow and Purple wires) to the

chassis connection (Purple and Brown wires).

17. Connect all the coolant hoses.

18. Place panduit straps in the locations shown (5, 6)

19. If applicable, place the coolant hose from the throttle bodies

to the coolant bottle (7).

20. Secure the hose clamp over all coolant hose and fittings.

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