Snowmobile Polaris IQ (2007-2008 year). Manual - part 33

5.10

Engine and Cooling Systems

Crankshaft Truing

Lubricate the bearings and clamp the crankshaft securely
in the holding fixture. If truing the crankshaft requires
striking with a hammer, always be sure to re-check
previously straightened areas to verify truing. Refer to the

illustrations below. Use Crankshaft alignment kit PN
2870569.

NOTE: The rod pin position in relation to the dial
indicator tells you what action is required to
straighten the shaft.

Truing Examples

To correct a situation like this. Strike the shaft at point A 
with a brass hammer.

To correct a situation like the one shown in this. Squeeze 
the crankshaft at point A. You will use the tool from the 
alignment kit PN 2870569.

If the crank rod pin location is 180

°

 from the dial indicator 

(opposite of above), it will be necessary to spread the 
crankshaft at the A position as shown in illustration 3. 
When rebuilding and straightening a crankshaft, 
straightness is of utmost importance. Runout must be as 
close to zero as possible.

5.11

Engine and Cooling Systems

5

RECOIL ASSEMBLY

Rope Removal and Installation

1.

With the recoil housing removed from the engine, un-tie
any knots (handle) in the recoil rope and allow the pulley
to slowly unwind.

2.

Remove the nut, friction plate, friction spring, ratchet and
ratchet spring from the pulley.

3.

Lift the pulley straight out of the housing making sure the
spring is no longer connected to the backside of the pulley.

NOTE: If all of the recoil spring tension was
removed, the spring should stay inside the housing
when the pulley is removed.

4.

Inspect all components for signs of abnormal wear and tear.
Replace components as required. If replacing the rope, tie
a small square knot at one end. Push the knot firmly into
the pocket on the pulley.

5.

If the pulley recoil spring was removed during disassembly,
install the spring by spiraling the spring counterclockwise
toward the center of the housing.

6.

Lubricate the center shaft and spring with Premium grease.

7.

Wind the rope counterclockwise around the pulley as

viewed from the ratchet-side of the pulley.

8.

Pass the end of the rope through the hole in the housing. If
the rope guide was removed from the housing, reinstall it
before attaching the rope handle.

9.

Slide the pulley down the center shaft and into the housing
making sure the recoil spring re-engages the pulley tab.

10. Install the ratchet spring and ratchet into the pulley face.

The ratchet spring leg fits in the notch on the ratchet and
holds the ratchet in (retracted).

11. Install friction spring with one leg inserted in the bottom

hole on the ratchet.

12. Install nut and torque to 5 ft.lbs. (7 Nm).

13. Pull rope out to its full extension and align pulley notch with

rope hole in housing.

14. Using a needle nose pliers or hooked wire, pull a loop of

rope through the notch in the pulley.

15. Prevent the rope from being retracted by tieing a knot in the

rope on the outside of the housing at the rope guide hole.

16. Wind the recoil pulley counterclockwise until the spring

begins to bind. Unwind the pulley clockwise two
revolutions.

17. Pull on the rope to disengage it from the notch in the pulley.

Un-tie the knot in the rope and allow it to retract into the
housing.

18. Pull on the handle to verify proper operation.

NUT

FRICTION PLATE

FRICTION SPRING

RATCHET

RATCHET SPRING

ROPE

RECOIL PULLEY

RECOIL SPRING

TAB (ENGAGES INSIDE HOUSING)

TAB (ENGAGES INSIDE PULLEY)

ROPE GUIDE (HOLE)

CAUTION

Recoil spring under high tension. Always wear eye 

protection when working with recoil housing 

components.

5.12

Engine and Cooling Systems

EXHAUST VALVE MAINTENANCE

Exhaust Valve Assembly

Exhaust Valve Disassembly

1.

Remove the vent hose from the base.

2.

Remove the two horizontal cover fasteners securing the
valve assembly to the cylinder.

3.

Remove exhaust valve assembly from cylinder.

4.

Remove the gasket and discard. Remove the two vertical
cover screws to access the spring and bellows.

5.

Secure the guillotine, then apply heat to remove the bellows
cap nut.

6.

Separate the cap nut, bellows and bellows washer from the
guillotine.

7.

Remove the guillotine from the base.

Exhaust Valve Assembly

1.

Clean the threads of the guillotine with Primer N.

2.

Insert the base into the clean guillotine.

3.

Apply Loctite 2760 to the first 3 threads on the guillotine.

4.

Place the bellows washer, bellows and cap nut onto the
guillotine.

5.

Torque the cap nut to specification.

6.

Lubricate the guillotine blade and shaft with engine oil.

7.

Actuate the guillotine to ensure full and free motion.

8.

Install the spring, and cover.

9.

Torque the vertical cover fasteners to specification.

10. Install a new gasket on the cylinder, then install the EV

assembly. The guillotine shaft will only fit into the cylinder
the correct way. If the shaft will not slide in, verify it is
installed correctly.

11. Torque the horizontal cover screws to specification.

Optional Exhaust Valve Springs

CAUTION

EV spring under tension. Use care when removing
housing from assembly base.

= T 

Guillotine Cap Nut Torque: 16 Ft.Lbs. (22 Nm)

GUILLOTINE

GASKET

EV BASE w/FITTING

BELLOWS WASHER

BELLOWS

CAP NUT

SPRING

COVER

VERTICAL SCREWS

HORIZONTAL SCREWS

= T 

Cover/Base Fastener Torque: 12 Ft.Lbs. (16 Nm)

SPRING

COLOR

LOAD

 @ 1 

INCH

(

LBS

.)

LOAD

 @ .630 

INCHES

(

LBS

.)

7041704-01

Blue

4.0

6.0

7041704-02

Orange

5.5

8.3

7041704-03

Pink

4.7

7.1

7041704-04

Purple

3.1

4.7

7041704-05

Yellow

2.4

3.6

7041704-06

White

1.6

2.8

5.13

Engine and Cooling Systems

5

ENGINE MOUNTING SYSTEMS

2007 IQ Carbureted Engine Mounting

NOTE:  Use an engine mount socket, PN: 2871989 to
remove the engine mounts from the bulkhead.

ENGINE ASSEMBLY

TORQUE STOP

SPACER

CLINCH PLATE

ENGINE MOUNT

ISOLATOR

ENGINE MOUNT

ENGINE MOUNT

ENGINE MOUNT BRACKET

A

A

A

A

A

A

A

A

A

A

A

B

C

C

C

C

= T 

A = 28 Ft.Lbs. (38 Nm)
B = 15 Ft.Lbs. (20 Nm)
C = 45 Ft.Lbs. (61 Nm)