Snowmobile Polaris 2006 - 2007 FS / FST. Instruction - part 28

 

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Snowmobile Polaris 2006 - 2007 FS / FST. Instruction - part 28

 

 

6.3

FS / FST Engine

6

Rev. 1 07/2006

Valve Seat Angle
Valve Outer Correction Angle
Valve Inner Correction Angle

45°
30°
75°

Valve Stem Diameter
- IV
- EV

5.465 - 5.479mm (.215

″)

5.456 - 5.470mm (.214

″)

Valve Guide I.D.

5.5mm (.216

″)

Valve Guide O.D.

6.535 - 6.546mm (.2572

″ -.2577″)

Valve Guide Exposed Height

8.1mm (.318

″)

Valve Stem-To-Valve Guide Clearance
- IV
- EV

.021 -.044mm (.0008

″ -.0017″)

.030 -.053mm (.0011

″ -.0020″)

Valve Stem Runout

.006mm (.0002

″)

Valve Lash Adjustment Shims
- Thinnest
- Thickest
-Increment Steps

2.5mm (.098

″)

3.7mm (.145

″)

.05mm (.002

″)

Valve Spring Free Length

38.2mm (1.5

″)

Valve Spring Installed Length

32mm (1.26

″)

Cylinder Head Warpage Limit

.04mm (.0015

″)

Cylinder Specifications
- Bore
- Taper Limit
- Out-Of-Round Limit
- Wear Limit

85 - 85.01mm (3.346

″)

.008mm (.0003

″)

.008mm (.0003

″)

Not Applicable - Nicasil Plated

Camshaft Specifications
- Width
- Intake Cam Lobe Height
- Exhaust Cam Lobe Height
- Camshaft Runout
    - At Sprocket
    - At Bearing Surface
- Radial Play
- Axial Play
- Bearing bore I.D.
- Camshaft Axle O.D.
- Distance Between Axle Clamps

108.85 - 109mm (4.28

″ - 4.29″)

48.553mm (1.911

″)

48.209mm (1.897

″)

.05mm (.0019

″)

.02mm (.0007

″)

.020 -.050mm (.0008

″ -.0019″)

.1 -.35mm (.0039

″ -.0137″)

25.9mm (1.019

″)

19.991 - 20mm (.787

″)

19.9 - 19.98mm (.7834

″ -.7866″)

109mm (4.291

″)

Rocker Arm Specifications
- Rocker Arm I.D.
- Rocker Arm Axle O.D.
- Rocker Arm Axle Holder Bore I.D.
- Rocker Arm Axial Play
- Rocker Arm Length

10.025 - 10.040mm (.395

″)

9.994 - 10mm (.393

″)

10mm   (.393

″)

.16 -.26mm (.0006

″ -.0010″)

77.4 - 77.5mm (3.04

″ - 3.05″)

Crankshaft Specifications
- Crankcase Bearing Bore I.D.
- Main Bearing Journal O.D.
- Connecting Rod Pin O.D.
- Crankshaft Deflection
- Main Bearing Clearance
- Bearing Codes

52 - 52.013mm (2.04

″)

47.96 - 47.98mm (1.888

″)

45.508 - 45.528mm (1.79

″)

.02 -.04mm (.0008

″ -.00015″)

.05 -.06mm (.002

″ -.0023″)

Yellow 1.995 - 2.000mm / Blue 2.000 - 2.005mm / Green 2.005 - 2.010mm

Connecting Rod Specifications
- Big End Oil Clearance
- Small End I.D.
- Bearing Codes
- Big End I.D. (Without Bearings)
- Big End Outside Width

.024 -.053mm (.0009

″ -.0021″)

20.995 - 21.011mm (.82

″ -.82″7)

Yellow 1.726 - 1.731mm / Blue 1.731 - 1.736mm / Green 1.736 - 1.741mm
49mm
23.8 - 23.9mm

FS / FST Engine Specifications

C

OMPONENT

S

PECIFICATION

6.4

FS / FST Engine

Rev. 1 07/2006

Balance Shaft Specifications
- Crankcase Bearing Bore I.D.
- Axial Play
- Radial Play
- Bearing Diameter
- Runout

28 - 28.013mm (1.102

″ - 1.103″)

.4 -.6mm (.0157

″ -.023″)

.014 -.066mm (.00055

″ -.0025″)

24.975 - 24.990mm (.983

″)

.014 -.066mm (.00055

″ -.0025″)

Piston Specifications
- Piston Orientation
- Piston-To-Cylinder Clearance
- Piston Diameter
- Wear Limit
- Piston Pin Boss I.D.
- Piston Pin O.D.
- Piston Wear Limit
    - At Piston Mating Surface
    - At Connecting Rod Mating Surface

Piston Pin C-Clip Notch Faces Intake-side of Engine
.017 -.052mm (.0006

″ -.002″)

84.935 - 84.965mm (3.34

″)

.04mm (.0015

″)

21mm (.826

″)

20.9 - 21mm   (.822

″ -.826″)

.004 -.016mm (.00015

″ -.0006″)

.005 -.016mm (.00019

″ -.0006″)

Piston Ring Specifications
- Top Ring Installed Gap
- Top Ring Groove Clearance
- Middle Ring Installed Gap
- Middle Ring Groove Clearance
- Oil Control Ring Installed Gap
- Oil Control Ring Groove Clearance

.25 -.50mm (.009

″ -.019″)

+/-.25mm (+/-.009

″)

.20 -.35mm (.007

″ -.013″)

.22 -.26mm (.008

″ -.010″)

.15 -.30mm (.005

″ -.011″)

.39 -.47mm (.015

″ -.018″)

Oil Pump Specifications
- Oil Pump Type
- Pressure Pump Rotor Tip Clearance
- Oil Pressure
    - Idle Speed
    - Maximum
Oil Pressure Relief Valve
    - Spring Free Length
    - Piston O.D.
    - Piston Length 

Scavenge (Low) and High Pressure Pumps
Not Measurable

1.2 Bar (17.4 psi)
5.5 Bar (80 psi)

69mm (2.71

″)

10.9mm (.429

″)

27.7 - 28mm (1.09

″ - 1.10″)

FS / FST Engine Specifications

C

OMPONENT

S

PECIFICATION

6.5

FS / FST Engine

6

Rev. 1 07/2006

Fastener Torque Specifications

FS / FST Engine Fastener Torque Specifications

C

OMPONENT

FT.LBS.

N

M

N

OTES

Valve Cover

6

9

Cylinder Head Nuts
- Step 1
- Step 3
- Step 4
Lower Crankcase Bolts
- Step 2
- Step 5

15
30

Turn 180°

12
18

20
40

Turn 180°

16
25

Apply Engine Oil to Crankcase Stud Threads

Apply Engine Oil to Lower Crankcase Fasteners

Camshaft Axle Clamps

7

10

Rocker Arm Towers

9

13

Fuel Rail

6

9

Intake Manifolds

6

9

Exhaust Manifold Nuts (NA and Turbo)

18

24

Water Outlet Manifold

7

10

Oil Filter Cover

18

24

Chain Guide (Fixed)

7

10

Apply Loctite

® 243 (BLUE)

Chain Tensioner Plug

51

70

Chain Guide (Tensioner / Pivot)

17

23

Apply Loctite

® 243 (BLUE)

Starter Motor

6

9

Water Pump Cover / Inlet Manifold

7

10

Apply Loctite

® 577 Thread Sealant

Water Pump Impeller

Hand Tight

Connecting Rod Caps
- Step 1
- Step 2
- Step 3

7

15

Turn 90°

10
20

Turn 90°

Apply Engine Oil to Threads

Balance Shaft Gear

51

70

Apply Loctite

® 272 (RED)

Engine Gear Cover

7

10

MAG Cover Panel

7

10

Upper Alternator Bracket / Pivot

15

20

Alternator Pulley

60

80

Apply Loctite

® 640 (GREEN) to flywheel taper.

MAG Engine Mount

30

40

PTO Engine Mounting Plates

Lower Alternator Mount
- Short Fastener
- Long Fastener

15
30

20
40

Lower Alternator Pivot Bolt

15

20

Scavenge Pump Filter Screen

7

10

Apply Loctite

® 243 (BLUE)

Scavenge Pump

7

10

Scavenge Pump Drive Gear

28

38

Apply Loctite

® 272 (RED)

Bed Plate

7

10

Ignition Coil Packs

6

9

6.6

FS / FST Engine

Rev. 1 07/2006

Cylinder Head / Crankcase Torque Patterns

Spark Plugs

20

27

Apply Anti-Seize Grease to Threads

Cam Phase Sensor

6

9

Intake Air Pressure Sensor

6

9

Coolant Temperature Sensor

13

18

Knock Sensor (Turbo)

14

20

Clean Fastener Threads and Leave Dry

Crank Position Sensor

7

10

Cylinder Head Plugs

7

10

Cylinder Head Air Bleed Nozzle

9

12

Apply Loctite

® 542 Thread Sealant

Turbo-to-Crankcase Oil Return Nozzle

30

40

Apply Loctite

® 577 Thread Sealant

Crankcase Plug

30

40

Bedplate-to-Oil Cooler Oil Nozzle

7

10

Cyclone Drip Return Banjo Bolt

13

18

FS / FST Engine Fastener Torque Specifications

C

OMPONENT

FT.LBS.

N

M

N

OTES

 

 

 

 

 

 

 

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