Snowmobile Polaris IQ (2007-2008 year). Manual - part 38

5.30

Engine and Cooling Systems

Disassembly / Assembly Process - 2008 800 CFI
Crankcase / Crankshaft

1.

Remove the engine from the engine compartment. 

2.

Follow the process for removing the cylinder head,
cylinders, pistons, flywheel / recoil housing, and the water
/ oil pump.

3.

Remove the intake boots, reed stuffers, and reed assemblies
from the intake tracks. Discard any seals or gaskets.

4.

Remove the fasteners from the bottom of the crankcase.
Carefully pry apart the crankcase halves. Discard the PTO
and MAG crankshaft seals.

5.

Remove the crankshaft.  Inspect as required.

6.

Thoroughly clean the two crankcase mating surfaces with
carburetor cleaner and a gasket remover. Flush out the
crankcase galleries.

7.

Reinstall the crankshaft back into the lower crankcase using
two new crankcase seals.

8.

Apply a thin bead of Three Bond 1215 to the lower
crankcase mating surface. Install the upper crankcase.

9.

Loosely install the crankcase fasteners, then torque to the
specifications at the beginning of the chapter. Use the
correct torque sequence when tightening the screws.

10. Liberally coat the crankshaft bearings and components with

Polaris two-stroke engine oil.

5.31

Engine and Cooling Systems

5

2007 - 2008 600 / 700 / 800 CFI Water / Oil 

Pump Assembly

Disassembly / Assembly Process

IMPORTANT: Use the mechanical seal installation

tool to install the water pump seal, PN: 2872010.

1.

Remove the coolant from the engine using a siphon, wet/
dry vac. or a drain pan.

2.

Remove the airbox, exhaust pipe and resonator. Remove
the hose connected to the water pump cover.

3.

To access the impeller and mechanical seal, remove the
water pump cover. Discard the water pump cover gasket.

4.

Remove the impeller nut, impeller and washers from the
cross shaft.

5.

Carefully pry the mechanical seal  and seal out of the
crankcase.

6.

Water pump assembly is the reverse of disassembly.
Always use new seals and gaskets during assembly.

7.

To remove the oil pump, remove the two fasteners then pull
the pump / cover out of the crankcase bore. Discard the

OIL PUMP

BEARING

CROSS SHAFT

WASHER

WASHER

O-RING

SEAL

MECHANICAL SEAL

WASHER

IMPELLER

NUT

WASTER PUMP COVER GASKET

WASTER PUMP COVER

TEE FITTING

C

B

A

= T 

A = 7 Ft.Lbs. (9.5 Nm)
B = 10 Ft.Lbs. (13 Nm)
C = 9 Ft.Lbs. (12 Nm)

5.32

Engine and Cooling Systems

gasket.

8.

To remove the oil pump / cover, remove the two fasteners
then pull the pump / cover out of the crankcase bore.
Discard the gasket.

9.

The cross shaft can be extracted from the water pump side
of the crankcase.

10. Assembly is the reverse of disassembly. Always use new

o-rings, seals and gaskets during assembly.

11. Install a new seal onto the shaft from the water pump side.

12. To install a new water pump seal, use the seal installation

tool, PN 2872010. Verify the seal lips are facing the cross
shaft gear.

600 / 700 / 800 CFI Oil Hose Routing

TEE FITTING

5.33

Engine and Cooling Systems

5

Engine Removal (Typical)

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

NOTE: 

The following removal and installation

process involves a CFI engine. Carbureted engines
do not use throttle bodies or the electrical
components housed in the drive clutch cover
electrical center.

1.

Open the hood, and remove the side panels. 

2.

Disconnect the battery ground (-) cable from the battery if
equipped.

3.

If equipped, unplug exhaust temperature sensor and
remove the exhaust system. 

4.

Remove the spark plug leads from the spark plugs.

5.

If equipped, remove the belt cover/electrical center cover.

6.

On CFI models, disconnect the intake air sensor located on
the MAG side of the airbox.

7.

On CFI models, remove the return fuel line “P” holder
located on the MAG side of the airbox.

8.

On CFI models, separate the fuel filter from the filter clip
that is on the MAG side of the airbox.

9.

Remove the airbox by removing the gear clamps, then
pulling the airbox assembly out of the engine compartment.

10. On CFI models, disconnect the main harness at the ECU.

This is the smaller of the two plugs located on the ECU.
Remove it by pressing up on the underside of the plug and
pulling straight off.

11. Disconnect the regulator/rectifier connections.