Snowmobile Polaris 2006 - 2007 FS / FST. Instruction - part 34

 

  Index      Snowmobiles / ATV     Snowmobile Polaris 2006 - 2007 FS / FST - instruction

 

Search            copyright infringement  

 

 

 

 

 

 

 

 

 

Content   ..  32  33  34  35   ..

 

 

Snowmobile Polaris 2006 - 2007 FS / FST. Instruction - part 34

 

 

6.27

FS / FST Engine

6

Rev. 1 07/2006

Starter Motor Assembly

KNOCK SENSOR

STARTER MOTOR

STARTER GEAR

WATER PUMP DRIVE GEAR

(TURBO only)

14 Ft. Lbs (20 Nm)

6 Ft. Lbs (9 Nm)

CLEAN THREADS

6.28

FS / FST Engine

Rev. 1 07/2006

DISASSEMBLY / ASSEMBLY

Valve Cover

1.

Remove the ignition coils. Replace packs if damage or
corrosion is found.

2.

Remove the valve cover.

3.

Inspect cover gasket, and spark plug hole gaskets for wear.
If gaskets are in good condition, replacement is not
required.

4.

Assembly is reverse of disassembly. Torque fasteners to
specifications listed in beginning of chapter.

Bedplate / Scavenge Pump

1.

Remove the engine from the engine compartment.

2.

Remove the fasteners that secure the bedplate to the lower
crankcase.

3.

Carefully pry the bedplate away from the lower crankcase.

4.

Remove the screen. Replace screen if damage is found.

5.

Remove the four fasteners securing the scavenge pump to
the bedplate.

NOTE:  The scavenge oil pump is not serviceable. 
Inspect the pump by rotating the drive gear in both 
directions. Motion should be smooth and never bind. 
Inspect each rotor tip for abnormal wear. Replace 
pump assembly if rotors bind or show signs of 
abnormal wear.

6.

Prior to assembly, clean the crankcase and bedplate mating
surfaces.

7.

Apply a thin bead of Three Bond 1215 to the bedplate
mating surface.

8.

Assembly is the reverse of disassembly. Torque fasteners
to specification listed in beginning of chapter.

Water Outlet Manifold-Thermostat Assembly

1.

To remove the thermostat from the outlet manifold,
remove the c-clip with a pair of snap ring pliers.

2.

Inspect the thermostat for any signs of damage and replace
if found.

3.

Test the thermostat by bathing component in a hot water
bath. Reference thermostat opening temperature
specification listed in the beginning of the chapter. Replace
if thermostat does not open at specified temperature.

6.29

FS / FST Engine

6

Rev. 1 07/2006

4.

To remove the water outlet manifold, remove the two
screws securing the manifold to the cylinder head.

5.

Prior to reassembly, replace o-rings with new. Coat the new
o-rings with a film of grease.

6.

Assembly is the reverse of disassembly. Torque fasteners
to specification listed in the beginning of this chapter.

7.

Verify thermostat cover snap ring is installed with the
chamfer facing out.

Water Pump Assembly

NOTE: 

Only the water pump cover, impeller,

mechanical seal, and water intake pipe can be
removed without removing gear cover.

1.

Suspend the engine inside the engine compartment. See
“Suspending Engine” on page 5.2.

2.

Siphon the coolant out of the main fill tube.

3.

Remove the hose connection the tee fitting to the radiator.

4.

Tip the tee fitting into a bucket. Pour out as much coolant
as possible.

5.

Remove the hose connection the tee fitting to the water
pump cover.

6.

Insert the siphon into the water pump cover and remove any
remaining coolant.

7.

Remove the oil tank bracket.

8.

Remove the MAG-side engine support plate.

9.

Remove the four screws securing the plastic cover to the
gear cover.

10. Remove the screw securing the intake pipe to the crankcase.

11. Discard the o-rings and cover gasket. Use new o-rings and

gasket during assembly.

12. To remove the impeller, insert the blades of two standard

screwdrivers into the impeller fins 180

° apart from each

other. Carefully turn the impeller counter-clockwise to
loosen while supporting the impeller fins with your fingers.

13. Remove the mechanical seal from the gear cover by

carefully pulling it out with a needle nose pliers. Discard
mechanical seal.

NOTE: 

Reference Front Gear Cover Assembly

section for water pump drive shaft, spacer, and
washer removal.

14. Assembly is the reverse of disassembly.

15. Install a new mechanical seal by carefully pressing the seal

evenly around the water pump drive shaft. Once seated,
firmly press inwards to set the seal.

16. Install the impeller by hand. DO NOT OVERTIGHTEN!

Tools are not required as the impeller rotates counter-
clockwise during operation.

17. Install a new water pump cover gasket into the cover, and

6.30

FS / FST Engine

Rev. 1 07/2006

new o-rings on the intake pipe. Push the intake pipe into the
cover and seat firmly.

18. Apply Loctite 542 to the two lower cover fasteners. Torque

cover and intake pipe fasteners to specification.

19. Reinstall the MAG engine mounting / alternator assembly.

MAG Gear Cover Assembly / Water Pump 

Driveshaft Removal and Installation

1.

Suspend the engine inside the engine compartment. See
“Suspending Engine” on page 5.2.

2.

Remove the water pump assembly. See “Water Pump
Assembly” on page 6.19.

3.

Remove the MAG-side engine mount bracket and upper
alternator support bracket.

4.

Remove the upper alternator support. Remove the heat
shield. Loosen the lower alternator pivot bolt. Push the
alternator towards the engine to relieve tension on the
alternator belt.

5.

Remove the alternator belt.

6.

Install the crank arrestor tool, PN: PS-48039 on to the PTO
shaft.

7.

Remove the pulley fastener while holding the crankshaft
stationary with the crank arrestor tool.

8.

Carefully tap the pulley off of the crankshaft using a soft-
face hammer.

9.

Remove the fasteners securing the gear cover to the engine.

NOTE: Front cover removal is not required when
removing the gear cover assembly. If removed, clean
mating surfaces and apply Three Bond 1215 to cover
mating surfaces during assembly.

10. Carefully tap the gear cover off of the engine using a soft-

face hammer.

11. Remove the water pump driveshaft from the front gear

cover. Using a small pick, remove the two gaskets located
inside the gear cover. Discard the gaskets.

12. Clean the gear cover and crankcase mating surfaces.

Remove all residual sealant from components.

13. Inspect the front cover seal. Replace seal if unevenly worn

or damaged.

14. To install new water pump driveshaft seals, use the seal

installation tool, PN:PS-48040.

15. To install a new front cover seal, use the front cover seal

installation tool, PN:PS-48043.

16. Assembly of the front gear cover / water pump drive shaft

is the reverse of disassembly.

17. Apply a thin bead of Three-Bond 1215 to the entire gear

cover-to-crankcase mating surfaces.

18. Torque fasteners to specifications listed in beginning of this

chapter.

 

 

 

 

 

 

 

Content   ..  32  33  34  35   ..