Snowmobile Polaris IQ (2007-2008 year). Instruction - part 31

 

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Snowmobile Polaris IQ (2007-2008 year). Instruction - part 31

 

 

5.2

Engine and Cooling Systems

ENGINE SPECIFICATIONS

Fastener Torque Guide

C

OMPONENT

600 / 700 CFI

800 CFI

600 HO

C

ARBURETED

NOTE

Spark Plug

18 Ft. Lbs. (24 Nm)

Apply Nyogel

Head Cover

25 Ft.Lbs. (34 Nm)

Loctite 242

Cylinder Head Bypass Fitting

7 Ft.Lbs. (9.5 Nm)

N/A

Bleed Screw

70 In.Lbs. (8 Nm)

Knock Sensor

168 In.Lbs. (19 Nm)

Clean and Dry

Temp. Sensor

18 Ft.Lbs. (24 Nm)

EV Housing Base / Cover

12 Ft.Lbs. (16 Nm)

Loctite 242

EV Bellows Nut

16 Ft.Lbs. (22 Nm)

Apply Loctite 2760 to the 

first 3 guillotine threads.

Cylinder Base Nuts

37 Ft.Lbs. (50 Nm)

N/A

37 Ft.Lbs. (50 Nm)

Cylinder Bolts

N/A

42 Ft.Lbs. (57 Nm)

N/A

PTO Crank Seal Guard

N/A

12 Ft.Lbs. (16 Nm)

N/A

Intake Boots

9 Ft.Lbs. (12 Nm)

Exhaust Manifold

22 Ft.Lbs. (30 Nm)

Oil Pump

7 Ft.Lbs. (9.5 Nm)

Water Pump Cover

9 Ft.Lbs. (12 Nm)

Recoil Housing

9 Ft.Lbs. (12 Nm)

Recoil Hub

9 Ft.Lbs. (12 Nm)

Flywheel Nut

90 Ft.Lbs. (122 Nm)

Loctite 242

Magneto

12 Ft.Lbs. (16 Nm)

5 Ft.Lbs. (7 Nm)

Loctite 242

Crankcase
M6

M8

22 Ft.Lbs. (30 Nm)

9 Ft.Lbs. (12 Nm)

Apply Loctite 242

22 Ft.Lbs. (30 Nm)

Apply Loctite 242

Engine Straps

30 Ft.Lbs. (41 Nm)

45 Ft.Lbs. (61 Nm)

Loctite 242

Water Pump Impeller

10 Ft.Lbs. (13 Nm)

Fuel Rail

9 Ft.Lbs. (12 Nm)

N/A

Crankcase Drain Plugs

60 In.Lbs. (7 Nm)

Apply Pipe Sealant

Air Intake Gear Clamps

11 In.Lbs. (1.2 Nm)

5.3

Engine and Cooling Systems

5

Engine Specifications

Engine Service Specifications - All Engines

• Cylinder Head Warp Limit = .006" (.015mm)

• Cylinder Taper Limit = .002" (.051mm)

• Cylinder Out-of-Round Limit = .002" (.051mm)

• Main Bearing Interference Fit:

Carbureted = .001" - .002" (.026 - .051mm)
CFI = .0014 - .0024 (.036 - .061mm)

• Connecting Rod Side Clearance = .0114" - .0295"

(.289 - .749mm)

• Crankshaft Runout Deflection Limit = .0025" (.07mm)

ENGINE

 

MODEL

 

NUMBER

INSTALLED

 

HEAD

 

VOLUME

(

CC

)

HEAD

 

SQUISH

INCHES

 (

MM

)

PISTON

-

TO

-

CYLINDER

 

CLEARANCE

INCHES

 (

MM

)

PISTON

 

RING

 

END

 

GAP

INCHES

 (

MM

)

TRIGGER

-

TO

-

FLYWHEEL

 

GAP

(

MM

)

S3273-6044-PU6F
S3274-6044-PU6F
S3466-6044-PU6F
S3467-6044-PU6F

27.6 - 28.9

.050 - .060

(1.283 - 1.544)

.004 - .006

(.105 - .159)

.014 - .020

(.356 - .508)

.4 - .8

S3206-6044-PU6H
S3468-6044-PU6H
S3469-6044-PU6H

26.65 - 28.15

.045 - .058

(1.143 - 1.482)

.36 - 1.34

S3305-7044-PF7J
S3470-7044-PU7J
S3471-7044-PU7J

29.3 - 30.85

.046 - .059

(1.17 - 1.51)

.0044 - .0059

(.112 - .151)

.017 - .026

 (.44 - .650)

S3322-7044-PF7J

.0042 - .006

(.109 - .163)

Upper

.010 - .018

(.25 - .45)

Lower

.014 - .020

(.35 - .50)

S3489-8044-PU8E
S3741-8044-PU8E

33.3 - 35.3

.049 - .065

(1.25 - 1.64)

.0037 - .0053

(.095 - .135)

.017 - .025

(.45 - .65)

5.4

Engine and Cooling Systems

Component Torque Sequences

Cylinder Head Torque Pattern (All)

CFI Crankcase Torque Pattern

Carbureted Crankcase Torque Pattern

Cylinder Torque Pattern (Except Monoblock)

Cylinder Torque Pattern (Monoblock)

CFI Recoil Cover

MAG

PTO

MAG

PTO

MAG

PTO

MAG

PTO

MAG

PTO

5.5

Engine and Cooling Systems

5

ENGINE INSPECTIONS

Cylinder Head Inspection

Using a flat bar and a feeler gauge, inspect each cylinder
head for warping. Replace head if warping exceeds .003

"

(.08mm).

Cylinder Measurement

Inspect each cylinder for wear, scratches, or damage. If no
damage is evident, measure the cylinder for taper and out
of round with a telescoping gauge or a dial bore gauge.
Measure the bore 1/2

"

 from the top of the cylinder; in line

with the piston pin and 90

°

 to the pin to determine if the

bore is out of round. Repeat the measurements at the
middle and bottom of the cylinder. Use the chart below and
record all measurements.

Crankshaft Runout Inspection

1.

Support the crankshaft in a set of “V” blocks as shown.

2.

Use a dial indicator to measure the runout at the following
locations:

• PTO end = First taper after bearing flat.

• MAG end = 1/2" from bearing flat.

3.

Runout deflection cannot exceed .0025" (.07mm).

4.

If the runout deflection exceeds the maximum
specification, crankshaft trueing may correct the deflection.

In. / mm. 

Cylinder Head Warp Limit

.006

"

 (.015mm)

Cylinder Measurement Worksheet

TOP

X

Y

MIDDLE

X

Y

BOTTOM

X

Y

Out-of-Round = Top X - Top Y and Bottom Y - Bottom X

Taper = Top Y - Bottom Y and Top X - Bottom X

In. / mm. 

Taper Limit = .002

"

 (.051mm)

Out-of-Round Limit = .002

"

 (.051mm)

 

 

 

 

 

 

 

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