Snowmobile Polaris (2006 year). Instruction - part 30

 

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Snowmobile Polaris (2006 year). Instruction - part 30

 

 

6.6

ENGINE

700/900 LIBERTY 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. 
Refer to the ‘INSPECTONS” on page 3.5 for
 general 
inspection procedures.

NOTE:  Make a note of the orientation and placement 
of every wire tie, hose clamp and spring clamp 
during engine removal. 

1.

Remove the side panels.

2.

Disconnect battery ground (-) if applicable.

3.

Remove the plenum and boost box. ‘IQ 700/900 AIR
INTAKE REMOVAL” on page 12.7

4.

Remove the belt. ‘DRIVE BELT REMOVAL WITH
TEAM CLUTCH” on page 7.5.

5.

Remove the exhaust system. ‘EXHAUST REMOVAL”
on page 3.16

6.

Remove the drive and driven clutches. ‘DRIVE CLUTCH
REMOVAL” on page 7.10 and ‘DRIVEN CLUTCH
REMOVAL” on page 7.20

7.

Drain coolant. (Drain the coolant, by disconnecting the
hose to the thermostat and apply air pressure to the
thermostat side while holding the disconnected hose into a
container).

8.

Remove the seat. ‘SEAT and FUEL TANK” on page 12.4

9.

Remove the fuel tank. ‘IQ FUEL TANK REMOVAL” on
page 12.5

10. Remove both fender plugs to access the fasteners for the

side braces.

NOTE:  Keep track of the orientation and placement 
of all fasteners, and cable ties.

11. Remove the left hand side brace and fuel filter.

12. Remove the right hand brace. The middle front fastener

has the hose guide.

13. Remove the two fasteners that hold the oil tank on the

chassis.

14. Drain the oil from the oil tank.

15. Remove the center shaft oil supply line from the oil tank.

16. Remove the fasteners that hold the coolant/oil tank onto

the chassis.

17. Remove the coolant bottle. ‘COOLANT TANK

REMOVAL” on page 12.3 

18. Remove the oil tank. ‘OIL TANK REMOVAL” on

page 12.3

19. Disconnect the exhaust valve hose from the base of the

exhaust valve base, and secure them out of the way.

20. Loosen the throttle adjustment lock nut and remove

throttle cable from the throttle body.

21. Disconnect the throttle cable from the throttle body.

22. Remove the coolant line that goes to the coolant bottle.

NOTE:  You may remove the throttle body at this 
time or when it is out of the chassis. See 
“THROTTLE BODY REMOVAL” on page 5.6

23. Disconnect the water temperature sensor connection (1)

from the harness, and move this harness out of the way.
The water temperature connectors are located in the
convoluted tubing near the cylinder base.

24. Remove the cable tie (2) that holds the TPS and water

sensor wires to the stator harness.

25. Disconnect the 4 fuel injector connectors (3) form the

CAUTION

Wear eye protection to prevent eye injury.

1

6.7

ENGINE

wiring harness located under the ECU area. Each injector
should be labeled.

26. Locate the fuel filter and remove the filter bracket (4), to

make room to remove the fuel line clip (5).

27. Remove the 3/8” fuel clip form the line and remove the

fuel filter. The supply line will stay with the engine.
‘FUEL CLIP REMOVAL” on page 12.3

28. Remove the fuel filter.

29. Disconnect the Regulator Rectifier (6) (yellow wires)

connector.

30. Disconnect the Stator Coil connector (7).

31. Disconnect the Crank Position Sensor connector (8).

32. Disconnect the DET sensor harness (9).

33. Route these connections through the chassis so that they

can come out with the engine.

34. Tilt the engine forward and route the rear cooling hoses, oil

lines, fuel lines and wiring so that the engine can be
removed.

35. Tilt the engine back and remove the two fasteners that hold

the front engine mount plate in the chassis.

36. Have an engine lift, lifting with slight pressure on the

engine and pull the engine forward to gain access to the

Injector Connection

2

3

4

5

6

7

8

9

6.8

ENGINE

cooling hoses, injectors and harness.

37. Place engine at work station.

700/900 LIBERTY ENGINE INSTALLATION

IMPORTANT: ALL Oil lines should have no air 
present in the lines.

1.

Make sure that you have everything on the engine as you
had when you removed the engine.

2.

Carefully lower the engine into the chassis.

3.

Align the front motor mount plate so that you can loosely
install the top plate fasteners. Do not tighten these at this
time.

4.

Tilt the engine forward and place a brace (1) between the
left rear motor mount and the bulkhead.

5.

Route coolant hoses, oil supply lines, wires and
connections around to the appropriate locations.

6.

Route the stator wires through the chassis, next to the
ECU.

7.

Route the DET connection through the chassis, next to the
ECU.

8.

First route the Mag side injector connectors through the
chassis, next to the ECU, then the PTO end injector
connectors.

9.

Hook up these connectors: PTO injectors, MAG injectors,
Stator, CPS. Make sure that the TPS and Water temp
sensor wires are routed behind the fuel lines.

10. Insert a new cable tie strap in the holder around these

wires.

11. Orientate these connectors like they were as best you can.

12. Tilt the engine back into the chassis and loosely install

both rear engine motor mount fasteners.

13. Install the lower front engine mount plate fasteners (2).

14. Torque the rear engine mounts to 29 ft-lb (39Nm).

15. Torque the front engine mount plate fasteners to 12 ft-lb

(16Nm).

16. Insert the throttle and oil cables onto the throttle body

assembly.

1

Wire routing next to ECU

ECU

Cable Ties

6.9

ENGINE

17. Insert a cable tie (3) around the coolant line and the throttle

cable at the top of the coolant line.

18. Install the throttle body on the intake boots.

19. Tighten the clamps on the throttle body.

20. Check oil pump alignment, and adjust to specification if

needed. ‘OIL PUMP ADJUSTMENT” on page 3.22

21. Check throttle cable free play, and adjust to specification.

‘THROTTLE LEVER FREE PLAY” on page 3.24

22. Attach the TPS harness (4) to the TPS sensor, and route a

cable tie (5) around the base of the sensor and the harness.

23. Attach the coolant line coming from the head to the right

hand side of the throttle body.

24. Install oil tank. ‘OIL TANK INSTALLATION” on

page 12.3

25. Install the coolant bottle. See “COOLANT TANK

INSTALLATION” on page 12.3

26. Hook up the exhaust valve lines back onto the base of the

exhaust valve.

27. Orientate the center crankshaft supply line (6) so that it is

closer to the engine and the fuel line (7) and the wiring
harness away from the engine. This supply line has heat
tape on the outside to protect it from heat.

28. Install the fasteners to the oil/coolant bottles.

29. Install the thermostat hose to the front of the head.

30. Insert the right hand engine brace by loosely installing the

rear center fastener (8) in first. This will enable you to
move the brace to center it.

31. Adjust the front of the brace so that the centering rivet is in

its place on the brace.

32. Install the three other fasteners on the front portion of the

brace.

NOTE:  The middle front fastener has the hose 
holder on the back side.

33. Torque all fasteners to 12 ft-lb (16Nm).

34. Install the fender plug.

3

TPS

4

5

7

6

Cable straps

8

 

 

 

 

 

 

 

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