Snowmobile Polaris Two Stroke (2007 year). Instruction - part 33

5.25

ENGINE

500/600 (Carbureted) 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 (Carbureted) Recoil/Stator

Installation

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 (7 N-m).

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 (122 N-m).

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

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

500/600 (Carbureted) Engine Installation

Make sure that you have the engine assembled so that it is
in the same state as it was when it was removed.

Place the engine on the shock tower bar and install the oil
pump cable.

Adjust the oil cable line so that the line is even (1) with the
index mark.

9 ft-lb

90 ft-lb

5 ft-lb

(12 N-m)

(7 N-m)

(122 N-m)

5.26

ENGINE

Install the oil supply line through the guide (2) on the MAG
intake.

Place the engine into the bulk head and make sure that it is
lined up with the motor mounts.

Insert the LH rear torque stop plate (3) between the motor
mount and the bulk head.

Apply blue Loctite to the fastener (4) and torque all the
outside fasteners (4,5) to 28 ft-lb(38 N-m).

Install the LH rear motor mount fastener (6) and torque to
28 ft-lb (38 N-m).

Insert the front engine strap washer and Nyloc nut (7) onto
the motor mount stud and torque to 28 ft-lb (38 N-m).

10. Adjust the front torque stop so that the bumper is bottomed

out on the plate, and lock the lock nut.

11. Insert the front isolator limiter assembly (8) and torque the

fasteners (9) to 28 ft-lb (38 N-m). See “Engine Isolator
Limiter Setting” on page 3.22.

12. Install the RH rear (10) and RH front (11) motor mount

washers and Nyloc nuts onto the motor mount studs.
Torque to 28 ft-lb (38 N-m).

= T

Motor Mount Nut: 28 ft-lb (38 N-m)

RH Rear

RH Front

5.27

ENGINE

13. Adjust both torque stops so that you have a clearance of

.010”-.030” (.25-.75mm).

14. Connect the Regulator Rectifier (12) and Stator (13)

connections.

15. Connect the thermostat cooling hose and secure it with the

clamp (14).

16. Connect the cooling hose going to the water pump (front

of engine) to the water bottle and secure it with the clamp.

17. Connect the impulse line from the fuel pump to the

crankcase.

18. Route the over fill hose (15) and secure it with a cable tie.

19. Connect the water temp sensor (16) and secure it to the

thermostat hose with a cable tie.

20. Connect the exhaust valve vent lines (18).

21. Install the oil supply lines to each of the carburetors.

22. Install the carburetors onto the carburetor boots and tighten

the clamps.

23. Connect the TPS sensor to the carburetors.

24. Install the two, Nyloc nuts and two T40 Torx bolts to the

front (19) and the two T40 to the rear (20) of the LH chassis
brace and install the brace.

NOTE: Install the long bolts and the spacer on the
front portion of the bar before inserting it into the
mounting area.

25. Replace the nosepan plugs.

26. Install the air box.

27. Install the driven clutch. See “Drive Clutch Installation” on

page 6.20.

= In. / mm.

Torque Stop Clearance: .010"-.030" (.25-.75mm)

5.28

ENGINE

28. Install drive clutch and belt. See “Driven Clutch

Installation” on page 6.21.

29. Route the recoil rope through the console and secure the

recoil handle.

30. Install the exhaust system.

31. Add coolant and bleed the cooling system.

32. Re-torque Drive Clutch to 50 ft-lb (69 N-m).

Torque Specifications

1 =Apply Loctite 242 to threads of bolt.

2= Apply Pipe sealant to threads.

3= See torque sequence.

ENGINE

500/600/600HO

SPARK PLUG

18 ft-lb (24 N-m)

CYLINDER HEAD

22ft-lb (30 N-m)1,3

BLEEDER SCREW

70 in-lb (8 N-m)

THERMOSTAT HOUSING

9 ft-lb (12 N-m)

WATER TEMPERATURE SENSOR

18-40ft-lb (24-54

N-m)2

WATER INLET PIPE

75ft-lb (102 N-m)2

DETIONATION SENSOR

168 in-lb(19 N-m)

CYLINDER BASE NUTS

32 ft-lb (43 N-m)3

EXHAUST VALVE COVER BOLTS

12 ft-lb (16 N-m)

EXHAUST VALVE NUT

144 in-lb (16 N-m)1

EXHAUST MANIFOLD BOLTS

22 ft-lb (30 N-m)

CARB ADAPTER BOLTS

108 in-lb (12 N-m)

OIL PUMP MOUNTING BOLTS

7 ft-lb (9 N-m)

CRANCASE PLUGS

10ft-lb (14 N-m)2

WATER PUMP IMPELLER NUT

120 in-lb (14 N-m)

WATER PUMP COVER BOLTS

108 in-lb (12 N-m)

CRANKCASE 6mm

9ft-lb (12 N-m)1,3

CRANKCASE 8mm

22ft-lb (30 N-m)1,3

ENGINE STRAP to CHASSIS NUT

18ft-lb (24 N-m)

ENGINE STRAP to ENGINE BOLT

45 ft-lb (61 N-m)

STATOR BOLTS

60 in-lb(7 N-m)1

TRIGGER COIL BOLTS

48 in-lb (5 N-m)

FLYWHEEL

90ft-lb (122 N-m)1

RECOIL CUP BOLTS

108 in-lb (12 N-m)

RECOIL COVER COLTS

108 in-lb (12 N-m)

DRIVE CLUTCH BOLT

50 ft-lb(68 N-m)

7/16” ENGINE MOUNT STRAP
BOLTS

45 ft-lb (61 N-m)

REAR MOTOR MOUNTS
BRACKET

29 ft-lb (39 N-m)

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