Snowmobile Polaris IQ (2007-2008 year). Instruction - part 37

 

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Snowmobile Polaris IQ (2007-2008 year). Instruction - part 37

 

 

5.26

Engine and Cooling Systems

2007 - 2008 600 / 700 / 800 CFI Recoil / Stator 

Assembly

Disassembly / Assembly Process

1.

Remove the exhaust pipe and resonator.

2.

If the recoil assembly does not require attention, the recoil
rope can remained attached to the handle. If recoil
component work is desired, reference the Recoil Assembly
section. 

3.

Remove the recoil / magneto housing cover. The recoil
assembly is located inside the housing.

4.

Remover the recoil hub from the flywheel. Secure the
flywheel with a strap wrench, PN PU-45419. Remove the
flywheel nut and washer.

5.

Using the flywheel puller tool, PN 2871043, insert the
puller’s three screws into the flywheel.

NOTE: Do not thread the puller screws into the
magneto/stator located behind the flywheel.

6.

Turn the puller center bolt in until the flywheel “pops” off
of the crankshaft.

7.

Mark the location of the magneto / stator plate in several
places using a scribe.

8.

Remove the magneto / stator from the crankcase.

9.

Assembly is reverse of disassembly. Reference the fastener
torque specifications at the beginning of the chapter.

10. Do not use an impact wrench to install the flywheel nut.

RECOIL HOUSING

SPRING

REEL w/ROPE

FRICTION PLATE

HUB

FLYWHEEL

STATOR (MAGNETO)

HANDLE

RATCHET

RETURN SPRING

BUSHING

FRICTION SPRING

RATCHET GUIDE

FLYWHEEL NUT

WIRE RETAINER

A

B

A

C

D

A

T 

A = 9 Ft.Lbs. (12 Nm)
B = 5 Ft.Lbs. (7 Nm)
C = 90 Ft.Lbs. (122 Nm) - Apply Loctite 242
D = 12 Ft.Lbs. (16 Nm) - Apply Loctite 242

5.27

Engine and Cooling Systems

5

2007 - 2008 600 / 700 CFI Crankcase / 

Crankshaft Assembly

1.

Remove the engine from the engine compartment. 

2.

Follow the process for removing the cylinder head,
cylinders, pistons, flywheel / recoil housing, and the water
/ oil pump.

3.

Remove the intake boots, reed stuffers, and reed assemblies
from the intake tracks. Discard any seals or gaskets.

4.

Remove the fasteners from the bottom of the crankcase.
Carefully pry apart the crankcase halves. Discard the PTO
and MAG crankshaft seals.

5.

Remove the crankshaft.  Inspect as required.

6.

Thoroughly clean the two crankcase mating surfaces with
carburetor cleaner and a gasket remover. Flush out the
crankcase galleries.

GEAR CLAMPS

INTAKE BOOTS

REED STUFFERS

REED BLOCKS

CYLINDER STUDS

NEEDLE BEARINGS

PTO SEAL

MAG SEAL

MAG BEARING

PTO BEARINGS

FLYWHEEL KEY

CRANKSHAFT

OIL INJECTION CHECK VALVE QTY. 5

ALIGNMENT DOWELS

A

B

C

In. / mm. 

Long Stud Height (Exhaust side) = 4.13

"

 (105mm)

Small Stud Height (Intake side) = 2.16

"

 (55mm)

T 

A = 9 Ft.Lbs. (12 Nm)
B = 22 Ft.Lbs. (30 Nm)
C = 10 Ft.Lbs. (13 Nm) - Apply Pipe Sealant

5.28

Engine and Cooling Systems

7.

Reinstall the crankshaft back into the lower crankcase using
two new crankcase seals.

8.

Apply a thin bead of Three Bond 1215 to the lower
crankcase mating surface. Install the upper crankcase.

9.

Loosely install the crankcase fasteners, then torque to the
specifications at the beginning of the chapter. Use the
correct torque sequence when tightening the screws.

10. Liberally coat the crankshaft bearings and components with

Polaris two-stroke engine oil.

5.29

Engine and Cooling Systems

5

2008 800 CFI Crankcase / Crankshaft

GEAR CLAMPS

ADAPTER PLATE

REED STUFFERS

REED BLOCKS

SEAL GUARD

PTO SEAL

ALIGNMENT DOWELS

MAG SEAL

MAG BEARING

FLYWHEEL KEY

PTO BEARING

WRIST PIN BEARINGS

OIL INJECTION CHECK VALVE QTY. 5

ALIGNMENT DOWELS

A

B

C

T 

A = 9 Ft.Lbs. (12 Nm)
B = 22 Ft.Lbs. (30 Nm) - Apply Loctite 242
C = 10 Ft.Lbs. (13 Nm) - Apply Pipe Sealant

 

 

 

 

 

 

 

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