Snowmobile Polaris IQ (2007-2008 year). Instruction - part 36

 

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Snowmobile Polaris IQ (2007-2008 year). Instruction - part 36

 

 

5.22

Engine and Cooling Systems

2007 - 2008 600 / 700 CFI Cylinder Head / 

Cylinders / Pistons

Disassembly / Assembly Process

1.

Remove the coolant from the engine using a siphon, wet/
dry vac, or drain pan.

2.

Remove the air box, exhaust pipe and resonator from the
engine compartment.

3.

Remove the high tension wires and spark plugs from the
cylinder head.

A

B

C

E

D

F

BLEED SCREW

GASKET

THERMOSTAT

THERMOSTAT COVER

HEAD COVER

TEMP. SENSOR

CYLINDER HEAD

O-RINGS

KNOCK SENSOR

O-RINGS

BASE GASKETS

CYLINDERS

PISTON RINGS

PISTON PIN

C-CLIP

PISTON

BEARING

T 

A = 70 In.Lbs. (8 Nm)
B = 9 Ft.Lbs. (12 Nm) - Apply Loctite 242
C = 25 Ft.Lbs. (34 Nm) - Apply Loctite 242
D = 18 Ft.Lbs. (24 Nm) - Apply Pipe Sealant
E = 168 In.Lbs. (19 Nm) - Clean and Dry
F = 37 Ft.Lbs. (50 Nm)

Piston Matrix

Engine Model

Piston PN

Piston ID

S3206-6044-PF6G

2203319

EK-22202c

S3468-6044-PU6H

S3469-6044-PU6H

S3305-7044-PF7J

2203512

2922-06

S3322-7044-PF7J

2203312

(Subs to 2203512)

EK-2486a

S3470-7044-PU7J

2203707

3050-00

S3471-7044-PU7J

2203606

(Single Ring)

2975-01

Piston Matrix

5.23

Engine and Cooling Systems

5

4.

Remove the thermostat housing outlet cooling hose from
the housing.

5.

Loosen all, then remove all head cover fasteners. Clean the
fastener threads to remove any thread locking residue.

6.

Discard the head cover and cylinder head o-rings. Always
use new o-rings during assembly.

7.

Inspect the cylinder head / combustion domes for any
damage. Measure cylinder head flatness. Replace cylinder
head if required.

8.

If only the cylinders are going to be removed, remove the
fuel rail from the upper fuel injectors. See “CFI Fuel Rail/
Injector(s) Removal/Installation” on page 4.30.

9.

Loosen all, then remove the cylinder bolts. Clean the bolt
threads to remove any thread locking residue.

10. Carefully pull each cylinder upwards taking care not to

drop the piston and rod abruptly against the crankcase.

11. Remove the cylinder base gaskets. Use a gasket scraper to

clean the gasket residue from the crankcase and cylinder
bases.

12. Inspect the cylinder walls. Nicasil cylinders can only be

lightly honed. Damage that cannot be removed with a light
hone requires cylinder replacement or re-chroming.

13. The assembly process is the reverse of disassembly.

14. Always use new gaskets and o-rings during assembly.

Liberally coat the inside of each cylinder and the outside
of each piston with Polaris two-stroke engine oil.

15. When installing a piston into a cylinder, verify each piston

ring opening is located at each piston ring locating pin.
Squeeze the top ring, then carefully slide the cylinder over
the compressed ring. Do the same with the bottom ring.

16. Follow the torque specifications and torque sequences

located at beginning of chapter when tightening fasteners.

5.24

Engine and Cooling Systems

2008 800 CFI Cylinder Head / Cylinder / 

Pistons

NOTE: Engines with serial number beginning with
S3489 feature a bypass nozzle.
Engines with serial number beginning with S3471
feature a plug.

BLEED SCREW

THERMOSTAT COVER

THERMOSTAT

SPARK PLUGS

GASKET

HEAD COVER

TEMP. SENSOR

THROTTLE BODY HOSE

PLUG*

BYPASS NOZZLE*

KNOCK SENSOR

PISTON

C-CLIP

PISTON RING

PISTON PIN

BASE GASKET

CYLINDER

CYLINDER HEAD

O-RINGS

* = SEE NOTE

O-RINGS

A

B

D

E

F

T 

A = 70 In.Lbs. (8 Nm)
B = 9 Ft.Lbs. (12 Nm) - Apply Loctite 242
C = 25 Ft.Lbs. (34 Nm) - Apply Loctite 242
D = 18 Ft.Lbs. (24 Nm) - Apply Pipe Sealant
E = 168 In.Lbs. (19 Nm) - Clean and Dry
F = 42 Ft.Lbs. (57 Nm)

Engine Model

Piston PN

Piston ID

S3489-8044-PU8E

2203605

(Single Ring)

2923-07

S3471-8044-PU8E

5.25

Engine and Cooling Systems

5

Disassembly / Assembly Process - 2008 800 CFI Cylinder
Head / Cylinder / Pistons

1.

Remove the coolant from the engine using a siphon, wet/
dry vac, or drain pan.

2.

Remove the air box, exhaust pipe and resonator from the
engine compartment.

3.

Remove the high tension wires and spark plugs from the
cylinder head.

4.

Remove the thermostat housing outlet cooling hose from
the housing.

5.

Loosen all, then remove all head cover fasteners. Clean the
fastener threads to remove any thread locking residue.

6.

Discard the head cover and cylinder head o-rings. Always
use new o-rings during assembly.

7.

Inspect the cylinder head / combustion domes for any
damage. Measure cylinder head flatness. Replace cylinder
head if required.

8.

If only the cylinder is going to be removed, remove the fuel
rail from the upper fuel injectors. See “CFI Fuel Rail/
Injector(s) Removal/Installation” on page 4.30.

9.

Loosen all, then remove the cylinder bolts. Clean the bolt
threads to remove any thread locking residue.

10. Carefully pull the cylinder upwards taking care not to drop

the pistons and rods abruptly against the crankcase.

11. Remove the cylinder base gasket. Use a gasket scraper to

clean the gasket residue from the crankcase and cylinder
base.

12. Inspect the cylinder walls. Nicasil cylinders can only be

lightly honed. Damage that cannot be removed with a light
hone requires cylinder replacement or re-chroming.

13. Inspect the crankcase and cylinder mating surfaces for

warping.

14. The assembly process is the reverse of disassembly.

15. Always use new gaskets and o-rings during assembly.

Liberally coat the inside of each cylinder bore and the
outside of each piston with Polaris two-stroke engine oil.

16. When installing a piston into a cylinder, verify each piston

ring opening is located at each piston ring locating pin.
Squeeze the top ring, then carefully slide the cylinder over
the compressed ring. Do the same with the bottom ring.

17. Follow the torque specifications and torque sequences

located at beginning of chapter when tightening fasteners.

 

 

 

 

 

 

 

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