Snowmobile Polaris 2006 - 2007 FS / FST. Instruction - part 36

 

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Snowmobile Polaris 2006 - 2007 FS / FST. Instruction - part 36

 

 

6.35

FS / FST Engine

6

Rev. 1 07/2006

13. Tighten the threaded ram securely against the plate while

keeping the pressing pin is square with the head of the chain
pin. Carefully press the pin through the first set of link
plates, but no further.

14. Release the tool, and perform procedure on the other end

of the same plate.

15. With both pins pressed out, remove the tool, then remove

the plate with chain pins and discard. Keep the chain
wrapped around the sprocket.

NOTE:  Do not drop the chain into the crankcase.

16. Hold the chain to the camshaft sprocket, then rotate the

engine so the cylinder is pointed down.

17. Rotate the crank arrestor tool in the direction of normal

engine travel until the chain is out of the crankcase.

18. Rotate the engine so that cylinder head is pointed up.

19. Loosen and remove the cylinder head nuts in even steps and

in a criss-cross pattern.

20. Remove the cylinder head assembly. Remove the cylinder

head gasket. Discard the gasket.

21. Perform the inspection procedures outlined in this chapter.

If the cylinder head is damaged or warped, etc., replace the

component.

NOTE: 

Valve guide, valve seat or head

reconditioning is not recommended. Repair options
include: replacing the complete cylinder head
assembly or, replacing the cylinder head casting and
transferring the original parts to the new head. The
cylinder head casting is fitted with new valve seats
and valve guides.

NOTE: Do not re-surface the cylinder head or
crankcase.

22. To remove the valves from the head assembly, reinstall the

four rocker arm shafts back into the rocker arm towers.

23. Using the valve compressor tool PN: PW-46991, compress

each valve, and remove the valve keepers from around each
valve stem.

24. Extract each valve from the combustion chamber side.

6.36

FS / FST Engine

Rev. 1 07/2006

25. Inspect each valve assembly for damage and abnormal

wear and tear. Reference the inspection procedures
outlined within this chapter. 

NOTE: Do not recondition valves. Replace worn
valves with new parts.

26. Remove the camshaft assembly by loosening the four

camshaft axle clamp fasteners

27. Tap the clamps softly with a rubber-faced hammer until

they break free from the axle. Mark each clamp to identify
original position during assembly.

28. Gently tap the axle and camshaft out of the cylinder head.

Inspect the axle and camshaft as outlined within this
chapter.

29. Remove the rocker arm towers by removing each fastener

at the base of the towers. Gently tap on the towers with a
rubber-faced hammer to remove.

30. Cylinder assembly is the reverse of disassembly. Tighten

fasteners to specified torque as outlined within this chapter.
Always use a new cylinder head gasket whenever the
cylinder head is removed from the engine.

31. Always install the camshaft so the arrow points in the

direction of camshaft rotation, not normal-operational
crankshaft rotation. The INTAKE and EXHAUST

direction of the camshaft are inscribed on the sprocket face.

KEYS

RETAINER

SPRING

SPRING CUP

VALVE

6.37

FS / FST Engine

6

Rev. 1 07/2006

Crankcase / Crankshaft / Pistons  / Balance 

Shaft

1.

Remove the engine from the engine compartment.

2.

Remove the following components / assemblies from the
engine:

• Valve Cover

• Sump / Bedplate

• Water Pump / Pump Components / Thermostat 

Manifold

• Gear Cover / Flywheel / Alternator Assembly

• Cylinder Head / Timing Chain / Chain Tensioner

• Starter  Motor

• High Pressure Oil Pump Assembly

3.

With the bottom of the engine facing upwards on the engine
stand, evenly remove the four lower crankcase fasteners.

NOTE:  The PTO-side fastener includes a clamp plate
for the oil pressure relief piston and spring
assembly. When removed, the spring and piston can
be extracted with a magnet.

4.

Using a soft-faced hammer, carefully pound each cylinder
head stud upwards in a criss-cross pattern. Doing so will
separate the lower crankcase from the upper crankcase
leaving the crank train and upper crankcase attached to the
engine stand.

5.

Remove the lower crankcase from the upper section.

NOTE:  Note the location of each of the four plastic
oil control stud jackets.

6.

Remove the balance shaft. Balance shaft bearings should be
replaced whenever the engine is disassembled due to the
fact that there is only one bearing size available.

7.

Remove the connecting rod fasteners. Carefully extract
each piston from the cylinder bores.

NOTE:  Make note of each connecting rod assembly.
The connecting rods feature “cracked” bearing cap
mating surfaces. No two connecting rod bearing cap
mating surfaces will be alike.

8.

Remove the crankshaft assembly from the crankcase.

NOTE: The timing gear is pressed on to the
crankshaft. Gear damage requires crankshaft
replacement.

With the engine completely dissembled, each part and
component should be thoroughly cleaned with engine cleaner.
Remove all sealants from mating surfaces using a razor blade or
brush.

After the engine parts are cleaned, inspect each part as outlined
within the “Engine Component Inspection” section within this
chapter. Always replace parts that do not meet specification
requirements with new parts.

Prior to re-assembling the engine, the connecting rod and
crankshaft main bearing oil clearances must be measured and
brought into specification as required.

6.38

FS / FST Engine

Rev. 1 07/2006

Connecting Rod Bearing Oil Clearance 

Inspection

NOTE: Do not move the crankshaft or connecting
rods until the measurement process is completed!

1.

Using the original connecting rod bearings, install each
piston back into the upper crankcase.

2.

Install the crankshaft.

3.

Wipe away any oil residue on the bearing surfaces.

4.

Place a piece of Plastigauge across the crankshaft
connecting rod journal surface.

5.

Install the connecting rod bearing cap with original bearing
installed. Torque fasteners to specifications.

6.

Remove the bearing cap, and measure the compressed
piece of Plastigauge at its widest point.

7.

Follow the Connecting Rod Bearing Replacement Guide.

Bearing Replacement Guide

NOTE:  The bearing color is imprinted on the side of
each bearing shell.

• CONNECTING ROD SPECIFIED OIL 

CLEARANCE: .024 - .053mm (.0009 - .0021in.)

• MEASURED OIL 

CLEARANCE:______________________

• ORIGINAL INSTALLED BEARING COLOR / 

THICKNESS:_______________________

REPLACEMENT BEARINGS (THICKNESS RANGE):

• RED (0451338):  1.721 - 1.726mm (.0677 - .0679in.)

• YELLOW (0451337):  1.726 - 1.731mm (.0679 - 

.0681in.)

• BLUE (0451339):  1.731 - 1.736mm (.0681 - .0683in.)

• GREEN (0451340):  1.736 - 1.741mm (.0683 - 

.0685in.)

• BROWN (0451341):  1.747 - 1.746mm (.0685 - 

.0687in.)

If the measured clearance is within specifications, replace
bearings with new bearings with the same color code.

If the measured gap is larger than specified, replace bearings
with the next larger bearing and re-measure.

If the measured gap is smaller than specified, replace bearings
with the next smaller bearing and re-measure.

Always measure the crankcase main bearing and connecting rod
big-end inside diameters and compare to specifications.
Replace components that are outside of specification.

If the original bearings reveal an oil clearance of .04 - .05mm,
install new bearings with the same color code as the originals.

 

 

 

 

 

 

 

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