Engine - the Polaris International Extranet
Contents
1. 36 Secure the gear stator housing cover O to the crankcase with the cover bolts Torque bolts to 96 12 in Ibs 10 85 0 35 Nm in proper tightening sequence see Pg 3 3 Remove seal protectors from the shaft ends once secure Gear Stator Housing Bolt Torque 96 12 in lbs 10 85 0 35 Nm Torque in Proper Sequence Pg 3 3 NOTE Before assembly clean the bolts and bolt holes with Primer N PN 2870585 to remove any debris This will ensure proper sealing when installing bolts 37 Install shaft seal with ceramic surface facing inward cT POLARIS 38 Install water pump impeller P Secure the impeller with the washer and a new nylok nut Q Torque the nut to 108 12 in lbs 6 8 0 68 Nm Water Pump Impeller Nut Torque 108 12 in Ibs 6 8 0 68 Nm 39 Install water pump cover R with new O ring seal Torque bolts to 96 12 in lbs 10 85 0 35 Nm in proper sequence See Pg 3 4 3 55 Install Dry Do not use lubricants or sealants on O ring Seal cl ie Gee S DR 96 12 in Ibs 10 85 1 35 Nm gt Water Pump Housing Bolt Torque 96 12 in Ibs 10 85 1 35 Nm Torque Bolts in Proper Sequence Pg 3 4 40 Sparingly apply Starter Drive Grease PN 2871423 to the starter drive Install the starter bendix NOTE There are thrust washers on both sides of starter drive 41 Install stator assembly S and bolts Torque bolts to 96 12 in2. 3 37 Flywheel Stator Installation 3 37 3 38 Engine Crankcase Disassembly Inspection 3 38 3 46 Camshaftinspection 3 46 3 47 Engine Crankcase Assembly 3 47 3 57 Troubleshooting 3 58 3 59 o ENGINE EXPLODED VIEW CRANKCASE i N Flange Seal EG Crankshaft EP Oil Pickup 60 6 in lbs 6 8 68Nm Crankcase Crankcase Bolts 22 2 ft Ibs 30 3 Nm SEE PAGE 3 10 FOR CRANKCASE BOLT TIGHTENING SEQUENCE 3 2 N ENGINE N Balance 98 10 in Ibs Shaft 11 1 13 Nm E 6 in Ibs 6 8 68 Nm Woodruff Key NOTE If needed heat the oil baffle bolts with a heat gun to remove No 192 24 in lbs Oil Plug 21 7 2 7 Nm Washer Apply Loctitet 242 to the bolt threads rara Apply White Lithium Grease aa Apply Moly Lube Grease cT POLARIS ENGINE S ENGINE EXPLODED VIEW Concave surface should be oriented against gear Split Gear Washer 22 2 ft Ibs 30 3 Nm Oil rotor Bolt Mag Gasket Cover Counterbalance Gear Washer aium L Impeller 22 2 ft Ibs Bolt p lt ers Washer Bolts 30 3 Nm 84 8 in Ibs 9 5 90 Nm Cb Gear S tator Coven d See Note Wire Hold Down Bolt Gear Stator Housing 96 12 in Ibs 10 85 35 Nm 108 12 in Ibs 6 8 68 Nm Oil Pump Bolt Tighten Sequence NOTE Apply Corr
3. Clean push rods A in a suitable solvent Blow dry push rods with compressed air 2 Use compressed air to confirm the oil passage is Clear in the center of the push rod Always wear Safety glasses when working with compressed air to prevent personal injury 3 Check the ends of the push rods A for nicks grooves roughness or excessive wear 4 The push rods A can be visually checked for straightness while they are installed in the engine by rotating them with the valve closed Push rods can also be checked with a dial indicator or rolled across a flat surface to check for straightness cT POLARIS 5 LO If the push rod A is visibly bent it should be replaced CYLINDER HEAD REMOVAL 1 2 Loosen the six cylinder head bolts evenly 1 8 turn each in a criss cross pattern until loose Remove bolts A and tap cylinder head B lightly with a soft face hammer until loose CAUTION Tap only in reinforced areas or on thick parts of cylinder head casting to avoid damaging the head or cylinder Remove cylinder head B and head gasket C from the cylinder D 3 21 o CYLINDER HEAD INSPECTION 1 Thoroughly clean cylinder head surface to remove all traces of gasket material and carbon CAUTION Use care notto damage sealing surface CYLINDER HEAD WARPAGE 1 Lay a straight edge A across the surface of the cylinder head B at several different points and measure warpage by inserting a
4. POLARIS ENGINE CYLINDER REMOVAL 1 Follow engine disassembly procedures to remove rocker cover and cylinder head 2 Tap cylinder A lightly with a rubber mallet in the reinforced areas only until loose 3 Rock cylinder forward and backward while lifting it from the crankcase supporting pistons and connecting rods Support pistons with Piston Support Block PN 2870390 VALVE LIFTER REMOVAL INSPECTION 1 Remove the valve lifter s by reaching into the crankcase and pushing the lifter up through the lifter bore by hand 2 Thoroughly clean the lifters in cleaning solvent and wipe them with a clean lint free cloth 3 Mark the lifters with a white pen if using the lifters forreassembly This will ensure thatthe lifters are properly placed during engine reassembly CF POLARIS o 4 Check the lifters for wear or scores 5 Check the bottom end of lifter to make sure that it has a slight convex 6 Ifthe bottom surface has worn flat it may be used with the original camshaft only Inspect Hydraulic Lifter NOTE Lifters that are scored worn or if the bottom is not smooth should be replaced with new lifters and cam as an assembly If replacing the lifters the camshaft should also be replaced PISTON REMOVAL 1 Remove circlip A Mark the piston with a white pen to ensure proper orientation if reused during assembly NOTE If the pistons are to be reused reassemble the pistons in the sam
5. This Side Out This indicates the side of the gear that faces outward or away from the case z gi yA N d l ee r worl erl S 3 51 o 25 Install counter balance shaft gear J with new key aligning timing marks with crankshaft gear 1 Install washer and bolt Use the Gear Holder PU 45838 Torque to 22 2 ft lbs 30 3 Nm PU 45838 Balance Shaft Gear Bolt Torque 22 2 ft lbs 30 3 Nm 26 Use the Cam Gear Alignment Tool PU 45497 2 to align the teeth of the cam gear M Install the cam gear M with the Cam Gear Alignment Tool still in place onto the camshaft The timing marks on the camshaft gear should align with the keyway on the balance shaft gear e oe PU 45497 2 T iva NOTE If the timing mark on the camshaft gear does not align properly remove the camshaftgear and tool Use the Cam Spanner Wrench PU 45498 to rotate the cam to the proper position NOTE Cam Spanner Wrench PU 45498 is only needed to rotate the camshaft when the entire valve train is assembled NOTE Before installing the balance shaft gear bolt and washer apply lithium grease between the washer 3 52 ENGINE and balance shaft gear 27 Reinstall the camshaft gear so the timing marks are properly aligned Install the washer and bolt Orientate the washer so the concave side is against the gear Torque to 22 2 ft lbs 30 3 Nm NOTE Be sure all of the timing marks are pro
6. Repeat for exhaust valves by pouring fluid into exhaust port VALVE TRAIN EXPLODED VIEW ROCKER ARMS ra 9 9 HYDRAULIC LIFTERS VALVES 328 POLARIS ENGINE S ENGINE HEAD REASSEMBLY 4 Apply assembly lube to push rods D and install into lifters Before reassembly clean the bolts and bolt holes with Primer N PN 2870585 to remove any debris This will ensure proper sealing when installing bolts 1 Install the head gasket A on the cylinder B 2 Install cylinder head on cylinder 3 Lubricate threads and top of washers underside of bolt head with engine oil Install head bolts C Torque to 35 4 ft Ibs 47 5 5 5 Nm in sequence provided P g 3 10 Allow the gasket to set for 1 minute at this torque then turn bolts 90 1 4 turn in sequence Refer to Page 3 10 for tightening sequence Verify pushrods are engaged in lifters 7 Install rockers Be sure that tab of fulcrum F is seated in head stand off Torque bolts to 22 2 ft Ibs 30 3 Nm Cylinder Head Bolt Torque Torque in sequence to 15 2 ft Ibs 20 8 2 7 Nm allow the gasket to set for 1 minute then back off 5 turns incrementally in sequence Re torque in sequence to 35 4 ft Ibs 47 5 5 5 Nm Finalize torque sequence by tightening Rocker Arm Bolt Torque each bolt an additional 90 1 4 turn 22 2 ft Ibs 30 3 Nm TE PODLARIS 8 29 o ENGINE HEA
7. alignmentof the pistons to the connecting rods upon assembly Partially install the piston pins into the pistons NOTE To help align the pistons slide a rod that is close to the same diameter as the wrist pin holes to properly align them in the cylinder 14 Position cylinder and piston assemblies onto the connecting rods and push the piston pins through the piston and connecting rods 15 Install the piston pin keepers F The pin keeper ends should be installed at the 12 O clock position Place Pin Keeper F in 12 O clock position 3 49 o NOTE While installing piston pin clips cover all engine passages The clip could fall into the engine during installation 16 Install camshaft thrust plate G with new bolts Torque bolts to 98 10 in lbs 11 1 13 Nm NOTE New bolts have patch lock on the threads and do not require Loctitet 17 Assemble rotors as marked when disassembled Use a cleaner to remove the marks previously made on the rotors 3 50 ENGINE Line Up Marks 18 Apply moly lube lubriplate or oil to the rotors on the oil pump shaft NOTE The application of oil or lubriplate aids in priming the oil pump during initial engine start up Lubricate Rotors 19 Align the bolt holes and install oil pump assembly into crankcase Rotate the rotors in the housing during installation as this checks for binding if new rotors are used NOTE Forassembly of the gears the c
8. cylinders Polaris recommends using a rigid hone or arbor honing machine Cylinders may be wet or dry honed depending upon the hone manufacturer s recommendations Wet honing removes more material faster and leaves a more distinct pattern in the bore HONING TO DEGLAZE A finished cylinder should have a cross hatch pattern to ensure piston ring seating and to aid in the retention of the fuel oil mixture during initial break in Hone cylinder according to hone manufacturer s instructions or these guidelines G Honing should be done with a diamond hone Cylinder could be damaged if the hone is not hard enough to scratch the nicasil lining G Usea motor speed of approximately 300 500 RPM run the hone in and out of the cylinder rapidly until cutting tension decreases Remember to keep the hone drive shaft centered or cylinder centered on arbor and to bring the stones approximately 1 2 1 3 cm above and below the bore at the end of each stroke G Release the hone at regular intervals and inspect the bore to determine if ithas been sufficiently deglazed and to check for correct cross hatch NOTE Do not allow cylinder to heat up during honing G After honing has been completed inspect cylinder for thinning or peeling If cylinder wear or damage is excessive it will be necessary to replace the cylinder The cylinders are lined with a nicasil coating and are not repairable Hone only enough to deglaze the outer layer of t
9. feeler gauge between the straight edge and the cylinder head surface If warpage exceeds the service limit replace the cylinder head Measure at different points on the surface Bottom Side Vie Cylinder Head Warpage Limit 004 1016 mm Max CYLINDER HEAD DISASSEMBLY NOTE The following procedure is only for servicing the top end of the valve train when replacing valve springs or replacing valve seals Valve Train Servicing In some cases the valve train can be serviced while the cylinder head is still on the engine Keep all parts in order with respect to their location in the cylinder head 3 22 ENGINE Wear eye protection or a face shield during cylinder head disassembly and reassembly 1 Having already removed the valve cover rocker arms and pushrods align the cylinder to be worked on at top dead center Install the Valve Pressure Hose PU 45652 into the spark plug hole Hook the hose to an air compressor and Supply 50 to100 psi to the hose This will seatthe valves during valve spring removal Do not remove air from the hose at anytime until reassembly is completed 2 Using the Valve Spring Compressor PU 45257 compress the valve spring and remove the valve keepers NOTE A small parts magnet A can aid in the removal of the retainers B k PU 45257 Valve Spring Compressor PU 45257 Valve Pressure Hose PU 45652 NOTE To prevent damage to the valve seals do not compres
10. lifted manually 22 For engine installation reverse procedures 3 17 o ENGINE INSTALLATION NOTES After the engine is installed in the frame review this checklist and perform all steps that apply General Items 1 Install previously removed components using new gaskets seals and fasteners where applicable NOTE Properly route all electrical harnesses and re attach any fasteners or protective tubing Check for any possible rubbing points of electrical wires 2 Perform regular checks on fluid levels controls and all important areas on the vehicle as outlined in the daily pre ride inspection checklist refer to Chapter 2 or the Owner s Manual 1 Adjust center distance of drive and driven clutch Chapter 6 2 Adjust clutch offset deflection Chapter 6 3 Clean clutch sheaves thoroughly and inspectinlet and outlet ducts for proper routing and sealing Chapter 6 Transmission alignment and belt 1 Inspecttransmission operation and adjustlinkage if necessary Refer to Chapter 2 and Chapter 8 Exhaust 1 Replace exhaust gaskets Seal connections with high temp silicone sealant 2 Check to be sure all springs are in good condition Bleed Cooling System NOTE Follow coolant bleeding procedure outlined earlier in the chapter 3 18 ENGINE Engine Break In Period The break in period for a Polaris twin cylinder engine is defined as the first ten hours of operation or the time it ta
11. this four to five times until the valve is fully seated and repeat process for the other valve s Thoroughly clean cylinder head and valves CYLINDER HEAD REASSEMBLY NOTE Assemble the valves one ata time to maintain proper order 1 2 3 Apply engine oil to valve guides and seats Coat valve stem with molybdenum disulfide grease or OW 40 Synthetic oil Install valve carefully with a rotating motion to avoid damaging valve seal Valve seals should be installed after the valves are in the head to avoid valve seal damage Install new valve seals on valve guides cT POLARIS 5 6 Dip valve spring and retainer in clean engine oil and install Place retainer on spring and install Valve S pring Compressor PU 45257 Install split keepers with the gap even on both sides NOTE A small parts magnet can aid in installation of the keepers Repeat procedure for remaining valves When all valves are installed tap lightly with soft faced hammer on the end of the valves to seat the split keepers NOTE To prevent damage to the valve seals do not compress the valve spring more than necessary to install the keepers 3 27 S ENGINE VALVE SEALING TEST 1 Clean and dry the combustion chamber area A Refer to Page 3 25 for cleaning tips 2 Pour a small amount of clean solvent onto the intake port and check for leakage around each intake valve The valve seats should hold fluid with no seepage 3
12. 18 0299mm Limit 0039 10 mm NOTE Replace camshaft if damaged or if any part is worn past the service limit NOTE Replace engine block if camshaft journal bores are damaged or worn excessively ENGINE CRANKCASE REASSEMBLY WARNING After any reassembly or rebuild the engine must be primed using the Oil Priming Adapter PU 45778 and a 3 4 full oil filter before initial start up Follow Steps 45 46 in this section to properly prime the engine and to help aid proper engine break in NOTE Before assembly clean the bolts and bolt holes with Primer N PN 2870585 to remove any debris This will ensure proper sealing when installing bolts cT POLARIS o 1 Installoil pick up A if removed Torque bolt to 60 6 in Ibs 6 8 0 68 Nm 2 Install oil baffle weldment B Torque bolts to 60 6 in Ibs 6 8 0 68 Nm Oil Baffle Weldment amp Oil Pick Up Bolt Torque 60 6 in Ibs 6 8 0 68 Nm 3 Install the balance shaft Inspect balance shaft clearance C in both gearcase halves Rotate balance shaft to ensure that there is clearance between it and oil baffle weldment NOTE Always install new balance shaft bearings 3 47 S ENGINE 4 Apply Moly Lube Grease to cam journals and 7 Assemble the crankcase halves Apply LocTitet balance shaft bearing surfaces of the MAG case 242 PN 2871949 to the threads and pipe sealant halve Install cam and balance shafts to the bolt flan
13. 9 3 60 ENGINE cT POLARIS
14. D REASSEMBLY CONT D 8 Install breather plate and reed G into rocker cover H Lightly apply black RTV sealant to the outer edges of the breather reed The reed has a tab and will assemble one way only Torque the breather bolts to 20 5 in Ibs 2 5 0 55 Nm NOTE When applying RTV do not get any RTV inside the reed assembly 9 Place a new seal I into the bottom of the cover Be sure the seal is seated into the cover properly 20 5 in lbs 2 5 55 Nm REMINDER Before assembly clean the bolts and bolt holes with Primer N PN 2870585 to remove any debris This will ensure proper sealing when installing bolts 10 Install rocker cover Torque bolts to 84 8 in lbs 9 5 0 9Nm See Page 3 6 for proper torque sequence 84 8 in Ibs 9 5 0 9 Nm Rocker Cover Bolt Torque 84 8 in Ibs 9 5 0 9 Nm Torque In Proper Sequence Pg 3 6 3 30 ENGINE 11 Install thermostat J new O ring and thermostat housing Torque thermostat housing bolts to 84 8 in lbs 9 5 0 9 Nm bleeder screw if previously removed Install B leeder Screw Location Thermostat Housing Bolt Torque 84 8 in Ibs 9 5 0 9 Nm Thermostat Housing Bleeder Screw 70 10 in Ibs 8 1 13 Nm 12 Install and torque to 200 20 in lbs 1 4 14 Nm K See Pg 3 6 for placement 200 20 in Ibs 1 4 14 Nm Temperature Sender Torque 200 20 in Ibs 1 4 14 Nm cT
15. ENGINE LO CHAPTER 3 cT POLARIS ENGINE Engine Exploded Views S pecial Tools Piston Identification 3 8 Torque Specifications 3 9 Engine Fastener Torque Patterns 3 10 Engine Service Data 3 11 3 12 Cooling System Specifications 3 13 Cooling System Test 3 13 Coolant System Bleeding Procedure 3 14 3 15 Engine Removal Installation 3 16 3 17 Engine Installation Notes 3 18 Cylinder Honing 3 19 Oil Pressure Test FIOW 3 19 3 20 Rocker Arm Pushrod Inspection 3 21 Cylinder Head Disassembly Inspection 3 21 3 23 Valve Inspection qep VD ey ebay nd 3 24 Combustion Chamber 3 25 Valve Seat Reconditioning 3 25 3 27 Cylinder Head Assembly 3 27 Valve Sealing Test 3 28 Valve Train Exploded View 3 28 Engine Head Reassembly 3 29 3 30 CylinderRemoval 3 31 Valve Lifter Removal Inspection 3 31 Piston Removal 3 31 3 32 CylinderInspection 3 32 3 33 Piston Rod Ring Service 3 33 3 35 Starter Bendix Removal Inspection 3 36 Flywheel Stator Removal Inspection
16. R PV 43527 Oil F ilter Wrench 2200634 Valve Seat Reconditioning Kit PU 45257 Valve Spring Compressor Valve Pressure Hose 2871043 Flywheel Puller 2870390 Piston Support Block PU 45497 2 Cam Gear Tooth Alignment Tool PU 45497 1 Cam Gear Spring Installation Kit Tapered P ins PU 45498 Cam Spanner Wrench PU 45838 Gear Holder PA 44995 Water Pump Mechanical Seal Installer Universal Driver Handle PA 45483 Main Seal Installer PA 45658 Main Crankshaft Seal Saver PA 45401 Water Pump Seal Saver 2870975 Mity Vact Pressure Test Tool ACCESSIBLE COMPONENTS The following components can be serviced or removed with the engine installed in the frame The following components require engine removal for service G Flywheel G Counterbalance Shaft or Bearing s G Alternator Stator G Connecting Rod G Starter Motor Starter Drive G Crankshaft G Cylinder Head G Crankshaft Main Bearings G Cylinder G Crankcase G Piston RIngs G Camshaft G Rocker Arms G Oil pump Water Pump and Oil Pump Drive Gear Gear Train Components PISTON IDENTIFICATION Four stroke engine rings have a rectangular profile See texton P age 3 33 for ring installation Use the information below to identify pistons and rings NOTE The pistons have no directional identification marks New pistons are non directional Engine Model No Piston Diameter Standard Piston Identification ETT 3 8 cT POLARIS ENGINE S TORQUE SPECIFICATIONS TORQUE SPECIFICATION
17. RY OR BECOME LOST SHOULD THEY POP OUT 12 Remove all three springs using one of the tapered pins from the Tapered Pins PU 45497 1 PU 45497 1 13 With a white marking pen accent the timing mark on the gear that contains the springs Accent the Timing Marks 14 Inspect the gear teeth and the three tabs on the gears for wear CF POLARIS ENGINE Inspect Teeth amp Tabs Cam Gear Reassembly 15 Installthe new springs into the grooves of the cam gear Insert S prings 16 Insert the pointed dowels from the Tapered Pins PU 45497 1 into the cam gear cT POLARIS PU 45497 1 To assemble G Hold the spring with one finger G Start the pointed end of the tapered pin into the cam gear hole and slowly push the dowel through the hole until the end of the dowel is almost flush with the spring G Perform this procedure with all three tapered pins G Do not push the pins too far through orthe springs will pop out NOTE Do not remove the tapered pins at this time 17 Note in the photograph that the Tapered Pins PU 45497 1 are below flush with end of the springs This helps to align the three gear tabs during the next step e PU 45497 1 3 41 Cam Gear Spring Installation Tool Kit PU 45497 Tapered Pins PU 45497 1 Cam Gear Tooth Align Tool PU 45497 2 18 Line up the two gears using the timing marks and the three gear tabs that were referenced earlier Push the
18. S 700 700 in Lbs Nm ft lbs Nm Camshaft Gear Camshaft Thrust P late Throttle Body Adapter Bolts Counterbalance Gear Crankcase Bolts em o o O f re com TTT T amm aaan oO 8 mm E EE TN WENNER ETE Crankcase Breather Cylinder Head Bolts TEITE N NN iam MEEL ES ES R RH HS Flywheel umj ere Magneto Cover 6 mm 96 12 10 85 0 35 24 24 5 2 5 HERE EE Oil Baffle Weldment 5mm 60 6 6 8 0 68 a el Oil Drain Bolt Crankcase 12 mm 192 24 21 7 2 7 _ l Oil Fill Tube Bolt 5mm 50 5 5 64 0 56 __ EE 6 6 8 24 m x lt gt D N n lt gt 5 oS Oil Filter Pipe Fitting 20 mm oe 35 4 47 5 5 4 Oil Pick Up Oil Pressure Relief Plug Oil Pump Housing Screw Rocker Arm 5mm 60 6 6 8 0 68 IN WENE WE EIE IS 6 mm 84 8 9 5 0 9 14 mm 216 24 24 5 2 7 park Plug tarter Motor tator Assembly tator Housing 6mm 96 12 10 85 1 35 cm eass s 09 d emm waaoe S ro Temperature Switch Thermostat Housing LY Ln 3 3 Berk ESE emm TRR T nr TRR T TT TEE 1 emm SETEL H id EET Thermostat Housing Bleed Screw Timing Plug Trigger Coil Stator Wire Holddown Water Pump Housing Cover Water Pump Impeller Nut 6mm 84 8 9 50 0 90 i G DI WINE EE EE o 9 9 9 WI WwW NI Ww D G O 7 oO s O O lt oO 8 mm 108 12 12 1 35 Se
19. am gear and the crankshaft gear are stamped with This Side Out This indicates the side of the gear that faces outward or away from the case NOTE Before assembly clean the bolts and bolt holes with Primer N PN 2870585 to remove any cT POLARIS ENGINE debris This will ensure proper sealing when installing bolts and new Loctitet 20 Install oil pump housing bolts H The new bolts contain patch lock so Loctitet is not needed on the new bolts Torque bolts to 84 8in Ibs 9 50 0 90 Nm and follow the torque sequence on Pg 3 3 NOTE Occasionally spin the oil pump when installing bolts to check for binding of the rotors Oil Pump Bolt Torque 84 8 in Ibs 9 50 0 90 Nm Torque in Proper Sequence Pg 3 3 21 Apply Loctitet crankshaft 242 PN 2871949 to the 22 Before installing the crankshaft gear I heat the crankshaft gear to 250 F 121 C on a hot plate J cT POLARIS CAUTION The crankshaft gear is extremely hot Severe bums or injury can occur if the gear is not handled with extreme care and caution Follow the procedure below to help ensure safety 23 Use extreme caution when removing the crankshaft gear from the hot plate Use a pair of pliers and leather gloves when handling the crankshaft gear 24 Install the crankshaft gear I onto the crankshaft NOTE For assembly of the gears the cam gear and the crankshaft gear are stamped with
20. bly of the gears 6 Remove the gear stator housing bolts and remove the gear stator housing cover J and gasket from the crankcase Be sure to catch the excess oil from the crankcase TE PSR RES B39 o NOTE If replacing one of the gears it is recommended that all of the gears be replaced A gear kit is available in the parts book Cam Gear Removal 9 Use the Cam Gear Tooth Alignment Tool PU 45497 2 O to align the cam split gear assembly With the split gear aligned remove the bolt and cam gear assembly PU 45497 2 a As NOTE Install the Cam Gear Tooth Alignment Tool PU 45497 2 into the assembly hole counter clockwise from the timing mark as shown Cam Gear Alignment Tool PU 45497 2 Cam Gear Disassembly 10 Inspect the cam gear teeth and check to make sure there is spring tension offsetting the teeth between the two gears If there is no tension check the springs inside of the cam gear assembly 3 Loaded Spring 3 40 ENGINE 11 The cam gear assembly contains three loaded springs To open the cam gear assembly G Place the cam gear on a flat surface with the timing mark side facing up G While holding both gears together lightly work a small flathead screwdriver between the two gears G Remove the top gear The springs should stay in place CAUTION WEAR SAFETY GLASSES AT ALL TIMES USE CAUTION WHEN WORKING WITH THE TOP GEAR THE SPRINGS COULD CAUSE INJ U
21. bstructed a bypass valve contained in the filter allows oil to bypass the filter element At this point the oil is supplied to the main oil galley through a crankcase passage Oilis then diverted three ways from the main oil galley with the first path entering the camshaft bores onto the rear balance shaftjournal and then draining back into the crankcase sump The second oil path from the main oil galley feeds the lifter bores and then drains back to the crankcase sump The third oil path flows through a crankcase galley to the MAG side crankshaft journal and also to the front balance shaft journal and onto the crankcase sump The oil pressure switch is fed off the main oil galley Crankcase Sump Crankshaft Main Bearing Rod Crankshaft Bearings Main Bearing Counterbalance Bore Bore Bore MAGNETO SIDE Lifter Bores Counterbalance Bore Camshaft Bore PTO SIDE Oil Pressure Relief Main Oil Galley Crankcase Sump 320 POLARIS ENGINE ROCKER ARM INSPECTION 1 Markortag rocker arms in order of disassembly to keep them in order for reassembly 2 Inspectthe wear pad atthe valve end of the rocker arm for indications of scuffing or abnormal wear If the pad is grooved replace the rocker arm NOTE Do not attempt to true this surface by grinding 3 Check the rocker arm pad and fulcrum seat for excessive wear cracks nicks or burrs PUSH ROD INSPECTION 1
22. ce piston pin to pin 0 00059 0 0002 0 015 0 005 mm bore Degree of fit KA a must be a push by hand fit at 68 o o ooo Piston Piston ring installed Top ring Ring 0 01083 0 00295 0 075 mm ring Oil ring 0 0177 00984 0 45 0 25 mm Standard clearance Topring S 0 0019 0 00069 0 0475 0 0175 mm piston ring to ring Second _ 0 0177 0 00394 0 45 0 10 mm Second m groove ring 0 0017 0 000491 0 0425 0 0125 mm Connecting rod small end ID 789 78841 20 030 20 015 mm Connecting rod small end ra 0 00098 0 00039 HSE ee 0 010 mm dial clearance Connecting rod big end side clearance 0 01181 0 00591 FEEL REEL rT 30 20 15 mm Connecting rod big end radial clearance Se OE 00015 0 00006 0 0038 0 0015 mm Crankshaft Crankshaft runout limit 0 00236 0 060 mm sis 0 060 0 00236 0 060 mm sis KEY Std Standard OS Oversize ID Inner Diameter OD Outer Diameter Mag Magneto Side PTO Power Take Off Side 3 12 POLARIS ENGINE 3 COOLING SYSTEM COOLING SYSTEM SPECIFICATIONS System Capacity 3 25 Quarts Radiator Cap Relief 13 PSI Pressure Thermostat Starts opening 179 F servicing 82 C Fully Open 203 F 1 Open front hood 92 C 2 Removesurge tank hose from coolant filler neck 3 Connect a Mity Vact PN 2870975 to the filler neck nipple and pressurize system to 10 ps
23. d top off coolant Fill the surge tank to the full line 3 Leave the cap off of the radiator to alow any possible air to escape Start the engine and let it idle for 5 10 minutes or until the thermostat opens and allows coolant to flow through the system NOTE If there is air in the system you will see air bubbles forming through the radiator fill neck 4 Addcoolantas needed If no bubbles are seen at the filler neck the system should be purged of air 5 Install the radiator cap and turn off the machine WARNING Be sure to install the radiator cap before shutting off the engine Coolant may spit out of the radiator 3 15 o ENGINE REMOVE amp INSTALL LA WARNING Always wear safety glasses and proper shop clothing when performing the procedures in this manual Failing to do so may lead to possible injury or death 1 Clean work area 2 Thoroughly clean the engine and chassis 3 Disconnect battery negative cable 4 Remove the following parts as required G Seat G Storage Unit under driver seat Refer to Chapter 5 5 Remove middle dog house cover and remove 8 3 exhaust pipe bolts 2006 RANGER XP 6x6 EFI Remove springs from exhaust pipe and remove pipe Refer to PVT System Chapter 6 to remove outer clutch cover drive belt drive clutch driven clutch and inner cover Drain coolant and engine oil 16 10 11 12 ENGINE Remove the air breather line A Remove PVT
24. e cylinder and direction from which they were removed NOTE New pistons are non directional and can be placed in either cylinder 2 Remove piston circlip and push piston pin out of piston If necessary heat the crown of the piston slightly with a propane torch CAUTION Do not 3 31 LO apply heat to the piston rings The ring may lose radial tension 3 Remove top compression ring Using a piston ring pliers Carefully expand ring and liftit off the piston CAUTION Do notexpand the ring more than the amount necessary to remove it from the piston or the ring may break By hand Placing both thumbs as shown spread the ring open and push up on the opposite side Do not scratch the ring lands d Repeat procedure for second ring 5 Remove the oil control ring The oil control ring is a three piece design consisting of a top and bottom steel rail and a center expander section The top rail has a locating tab on the end which fits into a notch B in the upper oil ring land of the piston To Remove a Remove the top rail first followed by the bottom rail b Remove the expander SSU MS 3 32 ENGINE CYLINDER INSPECTION 1 Remove all gasket material from the cylinder sealing surfaces 2 Inspect the top of the cylinder B for warpage using a straight edge A and feeler gauge C Refer to Ill 1 and Ill 2 Cylinder Warpage 004 0 1 mm Max cT POLARIS ENGINE 3 Inspect cyli
25. e exploded views for notes or torque sequences T PELARE SCY S ENGINE ENGINE FASTENER TORQUE PATTERNS Tighten cylinder head cylinder base and crankcase fasteners in the following sequence outlined below CRANKCASE BOLT TIGHTEN SEQUENCE Jo 9 3 22 2 ft Ibs 30 3 Nm CYLINDER HEAD BOLT TORQUE SEQUENCE Lubricate threads between washer and underside of bolt head with engine oil Torque in sequence to 15 2 ft Ibs 20 8 2 7 Nm allow the gasket to set for 1 minute then back off 5 turns incrementally in sequence Re torque in sequence to 35 4 ft Ibs 47 5 5 5 Nm Finalize torque sequence by tightening each bolt an additional 90 1 4 turn 3 10 POLARIS ENGINE ZOO EFIENGINE SERVICE DATA Earned valve Camshaft Cam lobe height 1 308 0 0067 33 223 0 1702 mm 1 308 0 0067 33 223 0 1702 mm Camshaft journal OD 1 654 0 00039 42 0 010 mm 1 634 0 00039 41 50 0 010 mm PTO 1 614 0 00039 41 0 010 mm Camshaft journal bore 1 656 0 00039 42 07 0 010 mm ID zene 1 637 0 00039 41 58 0 010 mm 1 617 0 00039 41 07 0 010 mm Camshaft Oil clear EE 00118 0 00079 0 03 0 02 mm eee a End Play 0 0167 0 0098 0 425 0 25 mm Counter End Play 0 005 0 127 mm Balance Cylinder Surface warpage limit EES 0 1 mm Head Standard heigh
26. e scrubbed thoroughly with hot soapy water rinsed and dried completely Wipe cylinder bore with oil immediately to remove residue and prevent rust CT POLARIS NOTES 3 35 o S R 1 TARTER DRIVE BENDIX EMOVAL INSPECTION Remove stator housing bolts and remove housing Remove the flywheel nut and washer Install Flywheel Puller PN 2871043 and remove flywheel CAUTION Do not thread the puller bolts into the flywheel more than 1 4 or stator coils may be damaged Remove starter bendix assembly A Note the thrust washers located on both sides of the bendix Inspect the thrust washer for wear or damage and replace if necessary After the bendix is removed tap on the starter assembly B with a soft faced mallet to loosen the starter from the crankcase 3 36 6 ENGINE Inspect gear teeth on starter drive B Replace starter drive if gear teeth are cracked worn or broken Inspect the bendix bushing C in the mag cover for wear Replace as needed cT POLARIS ENGINE FLYWHEEL STATOR REMOVAL INSPECTION 1 remove Remove stator housing bolts and housing Remove flywheel nut and washer Install Flywheel P uller PN 2871043 and remove flywheel A CAUTION Do notthread the puller bolts into the flywheel more than 1 4 or stator coils may be damaged ea E 2871043 Use caution when removing the wire holddown B and the stator assembly C Do not ta
27. e shaft gear 2871043 23 Inspectthe crankshaft gear Q for broken or worn R teeth If the crankshaft gear does not need to Water Oil Pump Removal Disassembly bereplaced itdoes not need to be removed If the crankshaft gear is damaged remove the 26 Rotate the water oil pump gear S so that all four crankshaft gear with the Flywheel Puller PN bolts are visible though the gear Remove the four 2871043 bolts with a hex wrench Pull out the pump 24 Install the two puller bolts R Tighten the puller f bolts up so that the bolts are at equal length 27 Inspect the oil pump rotors for wear Mark the rotors with a white pen to ensure upon reassembly thatthe correct sides of the rotors are installed and mesh with the same edges as previously installed Mark Rotors D 25 Install the Flywheel Puller PN 2871043 and remove the crankshaft gear if needed NOTE If replacing the old rotors new replacement rotors will fit into the old oil water pump housing TE PELARE 3 43 S 28 Remove the oil pressure relief The oil pressure relief consists of a bolt washer spring and valve dowel Inspectthe the valve dowel for signs of possible obstructions Use compressed air to blow out any debris 29 Reinstall the valve dowel chamfered end first Install the spring washer and bolt Torgue the bolt to 22 2 ft Ibs 30 3 Nm 22 22 ftlbs 30 3 Nm Chamfered end first NOTE Be sure t
28. erly bent or carbon accumulated on sealing surface G Rocker arm sticking Backfiring G Speed limiter system malfunction G Fouled spark plug or incorrect plug or plug gap G Exhaust system air leaks G Ignition system faulty S park plug cap cracked broken Ignition coil faulty Ignition or kill switch circuit faulty Ignition timing incorrect S heared flywheel key G Poor connections in ignition system O Valve sticking cT POLARIS G G G G G G DO DO GG G Oo fA G G G G o Air leaks in intake Lean condition COOLING SYSTEM TROUBLESHOOTING Overheating Low coolant level Air in cooling system Wrong type mix of coolant Faulty pressure cap or system leaks Restricted system mud or debris in radiator fins causing restriction to air flow passages blocked in radiator lines pump or water jacket accident damage Lean mixture restricted injector vents fuel pump or fuel valve Fuel pump output weak Electrical malfunction Water pump failure Loose impeller Thermistor failure Cooling fan inoperative or turning too slowly perform current draw test Ignition timing misadjusted Low oil level S park plug incorrect heat range F aulty hot light circuit Thermostat stuck closed or not opening completely Temperature Too Low Thermostat stuck open Leak at Water Pump Weep Hole Faulty water pump mechanical seal coolant leak Faulty pump shaft oil seal oil leak 3 5
29. ervice limits Ring Piston Pin Measurement Locations j ETE L j F eeler Gauge Piston Pin O D 0 7874 7872 20 19 995 mm 3 Measure connecting rod small end ID Piston Ring to Ring Groove Clearance Top Ring Limit 0 0019 0 00069 0 0475 0 0175 mm Second Ring Limit 0 0017 0 00049 0 0425 0125 mm Connecting Rod Small End I D 789 78841 20 030 20 015 mm 3 34 POLARIS ENGINE PISTON RING INSTALLED GAP 1 Place each piston ring A inside cylinder B using piston to push ring squarely into place as shown See next page Piston Ring Installed Gap 700 Top Ring Limit 0 01083 0 00295 0 275 0 075 mm Second Ring Limit 0 0177 0 00394 0 45 0 10 mm Oil Ring Limit 0 0177 00984 0 45 0 25 mm NOTE Ring should be installed with the mark on the ring facing upward 2 Measure installed gap with a feeler gauge C at both the top and bottom of the cylinder REMINDER A difference in end gap indicates cylinder taper The cylinder should be measured for excessive taper and out of round 3 Ifthe bottom installed gap measurement exceeds the service limit replace the rings If ring gap is smaller than the specified limit file ring ends until gap is within specified range NOTE Always check piston ring installed gap after re boring a cylinder or when installing new rings A re bored cylinder should always b
30. exhaust duct B Remove the exhaust shield C Disconnectthe air intake hose D from the air box and remove the air intake hose 13 Disconnect the throttle body sensor E at the electrical connector Remove the clamps that secure the throttle body F to the air intake boot and engine intake boot Remove the throttle body F Insert a shop towel into the engine intake to prevent dirt from entering the intake port cT POLARIS ENGINE 14 Relieve the fuel pressure in the fuel rail refer to Chapter 4 FUEL INJECTION for proper procedure Carefully remove the fuel rail G and injectors 15 Remove the spark plug leads H 16 Remove the crank position sensor I located on the mag cover 17 Disconnect the coolant temperature sensor J from the left side of the cylinder cT POLARIS te 18 Disconnect the coolant hoses Properly dispose of any antifreeze from the engine or hoses 19 When removing starter cables note and mark ground cable and positive cable mounting angle and locations Remove cables 20 Remove all engine mount nuts and or engine mount plates 21 With all hoses and wires disconnected the engine can be pulled straight out of the chassis NOTE Rotating the engine to the left 90 degrees valve cover facing left may ease engine removal NOTE Use caution when lifting the engine out of frame Use an engine lift or other means if the engine is too heavy to be
31. face or slightly above and must be the proper width G Ifthe indicated seat contact is at the top edge of the valve face and contacts the margin area B it is too high on the valve face Use the 30 cutter to lower the valve seat G If too low use the 60 cutter to raise the seat When contact area is centered on the valve face measure seat width G Ifthe seatis too wide or uneven use both top and bottom cutters to narrow the seat 3 26 Proper Seat Contact On Valve Face Bottom 60 Seat 45 Top 30 uv Valve Seat Width Intake Std 047 1 2 mm Limit 055 1 4 mm Exhaust Std 0591 1 5 mm Limit 0711 1 8 mm cT POLARIS ENGINE VALVE SEAT RECONDITIONING CONT D 8 Clean all filings from the area with hot soapy water rinse and dry with compressed air Wear eye protection or a face shield when working with compressed air during cylinder 10 11 12 head disassembly and reassembly Lubricate the valve guides with clean engine oil and apply oil or water based lapping compound to the face of the valve NOTE Lapping is not required with an interference angle valve job Insert the valve into its respective guide and lap using a lapping tool or a section of fuel line connected to the valve stem Rotate the valve rapidly back and forth until the cutsounds smooth Liftthe valve slightly off of the seat rotate 1 4 turn and repeat the lapping process Do
32. gears back together using both hands and hold securely 19 Once the gears are pressed together firmly hold the gears together with one hand Carefully remove the Tapered Pins PU 45497 1 by pulling them out one ata time with the other hand 20 After the tapered pins are removed be sure the cam gear assembly is held together tightly Place the cam gear assembly on a flatsurface Use the Cam Gear Tooth Alignment Tool PU 45497 2 3 42 ENGINE R to align the teeth of the cam gears as shown in the picture NOTE Install the Cam Gear Alignment Tool PU 45497 2 into one assembly hole counter clockwise from the timing mark PU 45497 2 NOTE For ease of installing the Cam Gear Alignment Tool PU 45497 2 R use a twisting motion when pushing down on the tool 21 To remove the balance shaft gear the flat side of the camshaft P must face the balance shaft gear To rotate the camshaft use the Cam Spanner Wrench PU 45498 to rotate the camshaftso the flat side of the camshaftfaces the balance shaft gear NOTE This Cam Spanner Wrench PU 45498 is only needed to rotate the camshaft when the entire valve train is assembled If the rocker arms are removed the camshaft can be turned by hand 22 Remove the bolt and nut from the balance shaft gear Try to remove the balance shaft gear If the gear does not come off manually use the Flywheel Puller PN 2871043 to remove the CF POLARIS ENGINE balanc
33. ges Torque bolts to 22 2 ft Ibs 30 3 Nm following torque pattern on Page 3 10 Crankcase Bolt Torque 22 2 ft Ibs 30 3 Nm Torque in Proper Sequence Pg 3 10 8 Lubricate cam lobes and valve lifters with Moly Lube Grease Moly lube Cam Lobes 5 Install crankshaft assembly and apply engine oil to crank pins and rods D Apply Moly Lube Grease to the main journals and bearings Moly lube Lifters 9 Lubricate lifters with engine oil and install in the original order as removed in disassembly Apply Lubriplate or Moly Lube to the ends of the lifters NOTE Always replace the camshaftand lifters as a set 6 Apply Crankcase Sealant PN 2871557 to the top gearcase halve NOTE Do not apply sealant to cam relief hole E 3 48 _ qemmeem Pears ENGINE 10 Lubricate connecting rods with OW 40 engine oil 11 Install new cylinder gasket on crankcase Align gasket on the dowel pins for proper gasket alignment NOTE Gasket must be installed dry Do not use sealers or lubricants to hold in place during installation 12 Orientate the piston rings on the piston before installation into the cylinders Set the gaps of the rings every 120 see illustration Piston Ring Orientation 1 2 TOP RING SECOND RING La LOIL RING cT POLARIS o 13 Install piston assemblies into cylinder aligning the piston pin holes to ensure proper
34. he cylinder bore cT POLARIS EXAMPLE OF CROSS HATCH PATTERN IMPORTANT Clean the Cylinder After Honing It is very important that the cylinder be thoroughly cleaned after honing to remove all grit material Wash the cylinder in a solvent then in hot soapy water Use electrical contact cleaner if necessary to clean these areas Rinse thoroughly dry with compressed air and oil the bore immediately with Polaris 4 Cycle Lubricant to prevent the formation of surface rust ENGINE LUBRICATION Oil Type Polaris Premium OW 40 Synthetic PN 2871281 Capacity Approximately 2 U S Quarts 1 91 Filter PN 2540086 Filter Wrench PV 43527 or equivalent Oil Pressure Specification 35 39 PSI 5500 RPM Polaris OW 40 Synthetic Engine at operating temperature OIL PRESSURE TEST 1 Remove blind plug sender from left side of crankcase 2 Inserta 1 8 NPT oil pressure gauge adaptor into the crankcase and attach the gauge 3 Start engine and allow it to reach operating temperature monitoring gauge indicator NOTE Use only Polaris Premium OW 40 Synthetic Engine Lubricant Oil Pressure at 5500 RPM Engine Hot Standard 39 PSI Minimum 35 PSI 3 19 S ENGINE OIL FLOW This chart describes the flow of oil through the EH68 engine Beginning in the crankcase sump the oil is drawn through an oil galley to the feed side of the oil pump The oil is then pumped through the oil filter If the oil filter is o
35. he gear stator housing cover must be resealed Clean the gearcase surfaces and reseal with a new gasket Refer to the Lower Engine Disassembly section and the Lower Engine Assembly section for details Inspect the areas pointed out in the illustration for possible oil seepage ED BG il SN IE 7 NE FLYWHEEL STATOR INSTALLATION 6 Install stator housing with new O rings Torque the bolts to 96 12 in lbs 1 85 1 35 Nm Follow bolt torque sequence on Pg 3 4 96 12 in lbs 3 38 ENGINE Stator Housing Bolt Torque 96 12 in Ibs 1 85 1 35 Nm Torque Bolts In Sequence Pg 3 4 ENGINE CRANKCASE DISASSEMBLY INSPECTION 1 Remove the stator cover A and water pump cover B 2 Remove the nylok nut C washer D and water pump impeller E Remove part of the water pump seal behind the impeller cT POLARIS ENGINE 3 Remove flywheel nut and washer 4 Install Flywheel Puller PN 2871043 and remove flywheel F CAUTION Do notthread the puller bolts into the flywheel more than 1 4 or stator coils may be damaged 5 Remove the starter bendix G wire holddown plate H and the woodruff key 1 from the crankshaft The stator does not have to be removed at this point 8 Usea white pen to accent the timing marks on the following gears camshaft gear K crankshaft gear M or counterbalance gear N This will ensure proper gear alignment and timing during reassem
36. i The Never remove radiator cap when engine is warm or hot The cooling system is under pressure and serious burns may result Allow the engine and cooling system to cool before Recommended Coolant Use only high quality antifreeze coolant mixed with system must retain 10 psi for five minutes or distilled water in a 50 50 or 60 40 ratio depending on longer If pressure loss is evident within five freeze protection required in your area CAUTION minutes check the radiator hoses clamps and Using tap water in the cooling system will lead to a water pump seals for leakage buildup of deposits which may restrict coolant flow and Radiator Cap Pressure Test reduce heat dissipation resulting in possible engine l damage Polaris Premium 60 40 Antifreeze Coolant is 1 Remove radiator cap and test cap using a recommended for use in all cooling systems and comes commercially available cap tester pre mixed ready to use 2 Theradiator cap relief pressure is 13 lbs Replace cap if it does not meet this specification Radiator Cap Thermostat Cylinder Head Coolant Flow Diagram Radiator Left Side View lt K To Water Pump TE POLARIS 3 13 o ENGINE COOLING SYSTEM EXPLODED VIEW Outlet Engine Hose Engine Inlet Hose a r E E Surge Tank Polaris Premium Antifreeze 2871534 Quart 2871323 Gallon COOLING SYSTEM BLEEDING PROCEDURE Always wear safety glasses and proper shop clothing when performing the p
37. kes to use two full tanks of gasoline No single action on your part is as important as a proper break in period Careful treatment of a new engine will result in more efficient performance and longer life for the engine Perform the following procedures carefully CAUTION Use only Polaris Premium 0 40W All Season synthetic oil or equivalent Never substitute or mix oil brands Serious engine damage and voiding of warranty can result Do not operate at full throttle or high speeds for extended periods during the first three hours of use Excessive heat can build up and cause damage to close fitted engine parts 1 Fill fuel tank with unleaded or leaded fuel which has a minimum pump octane number of 87 R M 2 2 Check oil reservoir level indicated on dipstick Add oil if necessary O SAFEO 3 Drive slowly atfirstto gradually bring engine up to operating temperature 4 Vary throttle positions Do not operate at sustained idle or sustained high speed 5 Perform regular checks on fluid levels controls and all important areas on the vehicle 6 Pull only light loads during initial break in 7 Change break in oil and filter at 20 hours or 200 miles cT POLARIS ENGINE CYLINDER HONE SELECTION AND HONING PROCEDURE CAUTION A hone which will straighten as well as remove material from the cylinder is very important Using a common spring loaded glaze breaker for honing is not advised for nicasil
38. l System P riming Adapter PU 45778 into the oil plug hole Push 3 5 oz approx of Polaris OW 40 into the adapter until resistance is felt Remove the adapter Apply pipe dope or Teflon tape to the plug threads Install the plug and torque to 216 24 in Ibs 24 4 2 71 Nm cT POLARIS Oil System Priming Adapter PU 45778 WARNING After any reassembly or rebuild the engine must be primed using the Oil Priming Adapter PU 45778 and a 3 4 full oil filter before initial start up Follow the steps in this section to properly prime the engine and aid proper engine break in Failure to perform this procedure may cause internal engine damage on initial start up 3 57 o TROUBLESHOOTING Spark Plug Fouling G G G G G S park plug cap loose or faulty Incorrect spark plug heat range or gap PVT system calibrated incorrectly components worn or mis adjusted Fuel quality poor old or octane too high Low compression Restricted exhaust Weak ignition loose coil ground faulty coil stator Restricted air filter main or pre cleaner or breather system Improperly assembled air intake system Restricted engine breather system Oil contaminated with fuel Engine Turns Over But Fails to Start G OOOOO G No fuel Dirt in fuel line or filter Fuel pump inoperative restricted Tank vent plugged or pinched Engine flooded Low compression high cylinder leakage No spark Spark plug fou
39. lbs 10 85 0 35 Nm 42 Install the the wire hold down bracket T Install two new wire hold down bolts New bolts contain patch lock Torque bolts to 96 12 in lbs 10 85 0 35 Nm and follow the proper bolt torque sequence on Pg 3 3 Coat the stator wire grommet U with Nyogelt Grease PN 2871329 3 56 ENGINE NOTE Be sure the stator wires are routed properly under the wire hold down bracket bolts with new bolts a Stator Assembly Bolt Torque 96 12 in Ibs 10 85 0 35 Nm 43 Install the flywheel washer nut and key Torque flywheel nut to 65 7 ft Ibs 88 9 50 Nm 65 7 ft Ibs 88 9 50 Nm Flywheel Nut Torque 65 7 ft Ibs 88 9 50 Nm 44 Install stator housing with new O rings Torque the bolts to 96 12 in Ibs 10 85 0 35 Nm and follow proper bolt torque sequence Pg 3 4 cT POLARIS ENGINE 45 46 96 12 in Ibs 10 85 0 35 Nm Stator Housing Bolt Torque 96 12 in Ibs 10 85 0 35 Nm Torque in Proper Sequence Pg 3 4 After the engine is completely assembled and ready for installation the engine must be properly primed with Polaris OW 40 Synthetic Oil PN 2871281 Fill the oil filter three quarters full with Polaris OW 40 Synthetic Oil PN 2871281 Let the oil soak into the filter for 8 10 minutes Install the filter onto the engine F ill 3 4 full with OW 40 oil Remove primer plug from the engine Install the Oi
40. led ignition component failure Engine Does Not Turn Over G G G Dead battery Starter motor does not turn Engine seized rusted or mechanical failure Engine Runs But Will Not Idle G G 3 58 Low compression Crankcase breather restricted ENGINE Engine Idles But Will Not Rev Up G O OO O G G G S park plug fouled weak spark Broken throttle cable Obstruction in air intake Air box removed reinstall all intake components Reverse speed limiter limiting speed Incorrect ignition timing Restricted exhaust system Cam worn excessively Engine Has Low Power G G G S park plug fouled Cylinder piston ring or valve wear or damage check compression PVT not operating properly Restricted exhaust muffler Cam worn excessively cT POLARIS ENGINE TROUBLESHOOTING CONT Piston Failure Scoring G Lack of lubrication G Dirt entering engine through cracks in air filter or ducts G Engine oil dirty or contaminated Excessive Smoke and Carbon Buildup G Excessive piston to cylinder clearance Wet sumping Worn rings piston or cylinder Worn valve guides or seals Restricted breather Oo aa G Air filter dirty or contaminated Low Compression G Cylinder head gasket leak G No valve clearance cam wear G Cylinder or piston worn G Piston rings worn leaking broken or sticking O Bent valve or stuck valve O Valve spring broken or weak G Valve not seating prop
41. lizes in this area NOTE The cylinder head valve guides cannot be replaced Wear eye protection or a face shield during cylinder head disassembly and reassembly Valve Seat Inspection Inspect valve seat in cylinder head for pitting burnt spots roughness and uneven surface If any of the above conditions exist the valve seat must be reconditioned Ifthe valve seat is cracked the cylinder head must be replaced Follow the manufacturers instructions provided with the valve seat cutters in the Cylinder Head Reconditioning Kit PN 2200634 Abrasive stone CF POLARIS o seat reconditioning equipment can also be used Keep all valves in order with their respective seat NOTE Valve seat width and point of contact on the valve face is very important for proper sealing The valve must contact the valve seat over the entire circumference of the seat and the seat must be the proper width all the way around Ifthe seat is uneven compression leakage will result If the seat is too wide seat pressure is reduced causing carbon accumulation and possible compression loss If the seat is too narrow heat transfer from valve to seat is reduced The valve may overheat and warp resulting in burnt valves OO TOO Uneven Good Wide 1 Install pilot into valve guide 2 Apply cutting oil to valve seat and cutter 3 Place 46 cutter on the pilot and make a light cut 4 Inspect the cut area of the seat G If the co
42. ll the crankshaft seal P with the seal lip facing out towards the crankcase Seal lip goes towards the crankcase 30 Once the crankshaft sealis installed into the gear stator housing cover setthe direction of the paper lip by sliding the Main Crankshaft Seal Saver PA 45658 into the crankshaft seal from the rubber lipped side to the paper lip side Back to Front Remove the tool Important Set the direction of Ai the paper seal lip Ha 3 53 LO 31 Carefully install the tapered end of the Crankshaft Seal Protection Tool PA 45658 through the paper side of the crankshaft seal Back to Front Leave the seal protector installed in the crankshaft seal Check the crankshaft seal lips to verify they have not been rolled or damaged leakage 32 Before installing the gear stator housing cover install the Water Pump Seal Saver PA 45401 onto the water pump shaft 33 Install the new gasket to the gear stator housing cover and crankcase With the tools installed carefully place the gear stator housing cover over the protection tools NOTE New gasket is not shown in the picture L crankcase 3 54 photos below ENGINE 34 Apply Crankcase Sealant PN 2871557 to the outside edges of the crankcase halves See arrows where the crankcases mate See This helps to prevent coolant 5 Install the gear stator housing gasket onto he cT POLARIS ENGINE Gear Stator Housing Gasket
43. nder for taper and out of round with a telescoping gauge ora dialbore gauge Measure in two different directions frontto back and side to side on three differentlevels 1 2 down from top in the middle and 1 2 up from bottom 1 2 Down From Top of Cylinder 1 2 Up From Bottom 4 Record measurements If cylinder is tapered or out of round beyond 002 the cylinder must be replaced Cylinder Taper Limit 002 05mm Max Cylinder Out of Round Limit 002I 05mm Max Standard Bore Size Both Cylinders 700 3 1496 80 mm 5 Inspect cylinder for wear scratches or damage cT POLARIS o PISTON TO CYLINDER CLEARANCE Measure piston outside diameter at a point 5 mm up from the bottom of the piston at a right angle to the direction of the piston pin Subtract this measurement from the maximum cylinder measurement obtained in Step 5 Piston Pin Piston to Cylinder Clearance 700 0016 00063 041 016 mm Piston O D 700 3 1477 000121 79 954 003 mm PISTON ROD INSPECTION 1 Measure piston pin bore Piston Pin Bore 700 0 00059 0 0002 0 015 0 005 mm 3 33 S ENGINE 2 Measure piston pin O D Replace piston and or 4 Measure piston ring to groove clearance by piston pin if out of tolerance placing the ring in the ring land and measuring with a thickness gauge Replace piston and rings if ring to groove clearance exceeds s
44. nly remove the oil baffle if the baffle is damaged When removing the oil baffle bolts use a heat gun to heat the bolts and loosen the Loctitet This will prevent any possible damage to the bolts or to the crankcase casting 38 Remove and clean oil pick up V and oil baffle weldment W C25 PELARE 345 40 Remove and inspect crankshaft main journal bearings for abnormal wear Itis recommended to replace the bearings anytime the engine is disassembled 3 46 ENGINE CAMSHAFT INSPECTION 1 Thoroughly clean the cam shaft 2 Visually inspect each cam lobe for wear chafing or damage Lobe height 3 Measure height of each cam lobe using a micrometer Compare to specifications Cam Lobe Height Intake amp Exhaust Std 1 308 0 0067 33 223 0 1702 mm 4 Measure camshaft journal outside diameters 0 D Journal O D s cT POLARIS ENGINE Camshaft J ournal O D A Mag 1 654 00039 42 010 mm B Ctr 1 634 00039 41 50 010 mm C PTO 1 614 00039 41 010 mm 5 Measure ID of camshaft journal bores Camshaft J ournal Bore I D Mag 1 656 0 00039 42 07 0 010 mm Ctr 1 637 0 00039 41 58 0 010 mm PTO 1 617 0 00039 41 07 0 010 mm 6 Calculate oil clearance by subtracting journal O D s from journal bore D s Compare to specifications Camshaft Oil Clearance Std 0 001
45. ntact area is less than 75 of the circumference of the seat rotate the pilot 180 and make another light cut G If the cutter now contacts the uncut portion of the seat check the pilot Look for burrs nicks or runout Ifthe pilot is bent it must be replaced 3 25 LO VALVE G SEAT RECONDITIONING CONT D If the contact area of the cutter is in the same place the valve guide is distorted from improper installation If the contact area of the initial cut is greater than 75 continue to cut the seat until all pits are removed and a new seat surface is evident NOTE ENGINE G Ifthe seatis too narrow widen using the 45 cutter and re check contact pointon the valve face and seat width after each cut NOTE When using an interference angle the seat contact point on the valve will be very narrow and is a normal condition Look for an even and continuous contact point all the way around the valve face B Remove only the amount of material necessary to repair the seat surface 5 To check the contact area of the seaton the valve face apply a thin coating of Prussian Bluet paste to the valve seat If using an interference angle 46 apply black permanent marker to the entire valve face A Insert valve into guide and tap valve lightly into place a few times Remove valve and check where the Prussian Bluet indicates seat contact on the valve face The valve seat should contact the middle of the valve
46. o place the tapered end of the valve dowel in first If the valve is installed incorrectly oil pressure and oil priming problems will occur 3 44 ENGINE DISASSEMBLY OF WATER OIL PUMP SHAFT WARNING Wear appropriate safety gear during this procedure Protective gloves clothing and eyewear are required 30 Carefully press the gear off the assembly while supporting the housing assembly Press off gear 31 Remove the snap ring from the assembly Place the housing in a support and press out the bearing shaft assembly E ka Press out shaft and bearing assembly S Bearing p Ring 32 Place the shaftin a press to remove the bearing Bearing cT POLARIS WATER OIL PUMP REASSE MB LY CRANKCASE DISASSEMBLY CONT D 33 Press new bearing onto the shaft 36 Remove thrust plate U ENGINE 3 iy Bearing 34 Press the bearing shaft assembly using the 37 Remove PTO end engine mount Remove bearing s outer race Do notuse the shaft to press crankcase bolts Tap on the reinforced areas on the assembly into the housing as bearing the cases using soft hammer Carefully separate damage may result Install retaining ring the two crankcase halves Press Bearing S haft assembly using oute race only Separate the crankcase halves 35 Press gear onto shaft while supporting the shaft NOTE O
47. osion Resistant Grease to Stator Grommet Area TIMING MARKS Mag Cover Bolt Tighten Sequence Apply Polaris OW 40 oil to component GEAR TIMING AT TDC rai EA AN TE PELARE 5 gt gt gt gt _ 33 o ENGINE EXPLODED VIEW Ia Apply Polaris Starter Grease Apply Polaris OW 40 Sl Oil to seal Loctitet Pipe Sealant PN 2871956 Bolts Tighten Top Bolt First 84 8 in lbs 9 50 0 9 Nm 108 12 in lbs 12 1 35 Nm Pos Cable Neg Cable Clamp Bolt Oil Fill Tube 50 5 In Ibs 5 64 0 56 Nm 3 4 ENGINE Water Pump Cover Bolt Tighten Sequence Water Pump Cover 96 12 in lbs 10 85 1 35 Nm 9 NO Grease or Oil EE 65 7 ft lbs Gasket E al 88 9 50 Nm Stator Cover Bolts 96 12 in lbs 10 85 1 35 Nm Hex Plug 144 12 in lbs 16 3 1 36 Nm Oil Filter Nipple 35 4 ft Ibs 47 5 5 4 Nm Oil Filter ne Stator Cover Bolt Tighten Sequence C2 POLARIS ENGINE ENGINE EXPLODED VIEW TOP END END Head Bolts Ee L 1 Lubricate threads and be Each N Thread tween washers and underside eee of bolt heads with engine oil Torque in sequence provided Apply Moly Lube grease to valve tips Gasket free of oil Verify tabs are visible 4 Apply thin film of OW 40 to 25 55 mm of cylinder bore 5 Apply 0W 40 to piston pin or pin bore 6 Apply OW 40 to lifters Do not install expansion pl
48. ound if necessary They must be replaced if extensively worn burnt bent or damaged Measure diameter of valve stem with a micrometer in three places then rotate 90 degrees and measure again six measurements total Compare to specifications 3 24 ENGINE Valve Stem Diameter Intake 0 2356 0 00039 5 985 0 01 mm Exhaust 0 2351 0 00039 5 972 0 01 mm Measure valve stem in several places Rotate the valve 90 degrees and mea sure for wear Measure valve guide inside diameter at the top middle and end of the guide using a small hole gauge and a micrometer Measure in two directions Valve Guide Valve Guide I D 0 2367 0 0003 6 0122 0 0075 mm Subtract valve stem measurement from the valve guide measurement to obtain stem to guide clearance NOTE The valve guides cannotbe replaced Be sure to measure each guide and valve combination individually cT POLARIS ENGINE COMBUSTION CHAMBER 1 Clean all accumulated carbon deposits from combustion chamber and valve seat area with carbon cleaner and a soft plastic scraper IMPORTANT Do notuse wire brush metal scraper or abrasive cleaners to clean the bottom of the cylinder head Extensive damage to the cylinder head may result Wear safety glasses during cleaning VALVE SEAT RECONDITIONING Cylinder Head Reconditioning NOTE Polaris recommends thatthe work be done by a local machine shop that specia
49. p or bump the gear stator housing cover or the stator This could cause the seal around the gear stator housing cover and the crankcase to break causing a leak cT POLARIS 5 Remove the bendix if necessary F LYWHEEL STATOR INSTALLATION NOTE Before assembly clean the bolts and bolt holes with Primer N PN 2870585 to remove any debris This will ensure proper sealing when installing bolts 1 3 Carefully install the stator and trigger coil to the gear stator housing cover Do nottap on the stator or the gear stator housing cover This may cause a leak in between the gear stator housing cover and the crankcase Properly place the stator wires under the wire holddown and installthe bolts Inspectthe bolts if new bolts are needed replace them with new bolts The new bolts contain patch lock so Loctitet is not needed on the new bolts Torque bolts to 96 12 in Ibs 10 85 0 35 Nm Apply a corrosion resistant grease to the rubber grommet to help keep contaminants from entering the stator area Install the starter bendix if removed 3 37 o 4 Install woodruff key Install the flywheel Install the flywheel washer and nut Torque the flywheel nut to 65 7 ft lbs 88 9 50 Nm Flywheel Nut Torque 65 7 ft Ibs 88 9 50 Nm 5 Inspect the mating surface around the gear stator housing cover and the crankcase for oil Seepage If there is seepage between the mating surfaces then t
50. perly aligned Timing Marks Water Pump Gear Counterbalance Gear and Camshaft Gear Bolt Torque 22 2 ft Ibs 30 3 Nm cT POLARIS ENGINE GEAR STATOR HOUSING SEAL REPLACEMENT IMPORTANT Due to seal design and construction these seals MUST be installed dry no lubricant during assembly Use of lubricants oil soapy water etc will not allow the seal to wear in and seal properly Do not touch seal surface or allow seal surface to come in contact with contaminates during installation Thoroughly clean parts tools and hands before installation 28 Before installing the gear stator housing replace the seals in the cover Install a new water pump seal N into the gear stator housing O Use the Water Pump Mechanical Seal Installer PA 44995 to properly install the seal to the correct depth in the cover PA 44995 NOTE To remove the water pump seal the gear stator housing must be removed The water pump seal cannot be removed or installed with the gear stator housing attached to the engine Shaft damage will occur NOTE Install the waterpump seal N with the seal lip facing out towards the crankcase Use of a hydraulic press is recommended for this procedure 29 Install a new crankshaft seal P into the gear stator housing cover O Use the Universal Driver Handle PU 45543 and the Main Seal Installer PA 45483 to seat the crankshaft seal into place cT POLARIS PU 45543 NOTE Insta
51. rocedures in this manual Failing to do so may lead to possible injury or death CAUTION Use caution when performing these procedures Coolant maybe hot and may cause severe injury or burns NOTE Use this procedure when a unit overheats and no apparent leaks in the cooling system are found NOTE If the coolant level is LOW in the radiator or if there are leaks in the system the coolant system will not draw coolant from the reservoir tank 3 14 Radiator Inlet Hose Pump hoses by hand x to help purge system Radiator Cap Radiator Outlet Hose ad SEZ a ee _ Radiator S hroud Drain _ x PROCEDURE 1 1 Park Machine on a flat surface Place the vehicle in Neutral and set the parking brake CAUTION Be sure the engine has cooled and there is no pressure built up in the cooling system before removing the radiator cap The coolant maybe hot and could cause severe injury or bums 2 Remove radiator cap A and top off coolant Remove surge tank B fill cap and fill the surge tank to the full line cT POLARIS ENGINE 3 Leave the cap of of the radiator to allow any possible air to escape Start the engine and let it idle for 5 10 minutes or until the thermostat opens and allows coolant to flow through the system 4 Slightly loosen the bleed screw C on the thermostat cover to let air escape If no air is present a steady stream of coolant will stream out If there is air present the screw
52. s the valve spring more than is needed to remove the valve keepers 3 Remove spring retainer and spring 4 The valve seals are now serviceable cT POLARIS ENGINE CYLINDER HEAD DISASSEMBLY CONT NOTE Carefully remove the cylinder components Place the hydraulic lifters C pushrods D and rocker arms E in a Safe clean area 5 Measure free length of spring with a Vernier caliper Compare to specifications Replace spring if measurement is out of specification Valve Spring Free Length cT POLARIS 7 Valve Spring Length Std 1 8271 46 40 mm Installed Height 1 47 37 34 mm Remove valve guide seals IMPORTANT It is recommended to replace seals whenever the cylinder head is disassembled Hardened cracked or worn valve seals will cause excessive oil consumption and carbon buildup Mark the valves with a white pen Remove the valves from the cylinder head This will ensure that the valves are properly placed during engine reassembly 3 23 o VALVE INSPECTION 1 2 Remove all carbon from valves with a soft wire wheel or brush Check valve face for runout pitting and burnt spots To check for bent valve stems mount valve in a drill or use V blocks and a dial indicator Check end of valve stem for flaring pitting wear or damage A Inspect split keeper groove for wear or flaring of the keeper seat area B NOTE The valves can be re faced or end gr
53. t 478 88 35 mm Valve Seat Contacting width S 0472 0 00787 0 0039 1 20 0 20 0 10 mm 1 50 0 20 0 10 mm rE 0 0591 0 00787 0 0039 Setane AI Valve Inner diameter lt lt o Inner diameter _ _ 0 2367 0 0003 6 0122 0 0075 mm Guide 03610 0 dad ae 25 0 10 mm S E Margin thick se por 0 005 aS 20 125 a ness a 0 070 0 005 WOED mm ooo 78 0 13 mm mame i oA N EN LE EO AE GED EG Stem oil clear Std in 0 0011 0 00098 0 0277 0 025 mm ance 0 0016 0 00039 0 0407 0 010 mm Overall length 4 51 0 01476 114 5550 0 375 mm 4 5453 01496 115 45 0 38 mm Overall length Free 1 8267 46 40 mm Length Installed 1 47 37 34 mm Height cT POLARIS 3 11 S ENGINE 700 EFI ENGINE SERVICE DATA Cylinder Piston Connecting Rod Cylinder Surface warpage limit mating with cyl 0 004 0 10 mm inder head Cylinder bore 3 1495 80 mm 0 000317 10 006 mmm Out of round limit eoeeeeeew 0 0075 mm Piston clearance T ooe 00063 041 016 GE ETER Lifter 0 84245 0 00025 21 39 84 0 00635 mm 0 8438 0 00062 21 4322 0 0157 mm EA ES Piston IS 3 1477 000121 79 954 003 mm Standard inner diameter of piston pin 0 78789 00000981 20 0125 0 0025 mm bore Piston Pin Outer diameter 0 7874 7872 20 19 995 mm Standard clearan
54. ug more than 1 5 mm inward A 1 5 mm y Side View 9 apply Polaris OW 40 oil B AI Apply Moly Lube Grease CT POLARIS Initial 15 2 ft Ibs 20 3 2 7 Nm to seat gasket and back off 5 turns Re torque to 35 4 ft Ibs 47 5 5 5 Nm Finalize sequence by tight ening an additional 90 1 4 turn OO Q Head Bolt Tighten Sequence Rocker Arms 22 2 ft Ibs 30 s3 Nm Piston Assembly a Circlip UP for Install 3 5 o ENGINE EXPLODED VIEW OUTER COMPONENTS Screws Dg 8 84 8 in lbs D 4 95 20 9 Nm T S Af a af ENGINE Breather Rocker Cover Spark Plug 216 24 in Ibs 24 5 2 7 Nm Apply Dielectric Grease Tips of Spark Plugs Throttle Body Adapter Bolts 216 24 in Ibs 24 5 2 7Nm 20 5 in Ibs Boo 2 5 0 55 Nm Apply Corrosion Resistant Grease K Exhaust Manifold 02 O Nm 3 6 Crank Position 84 8 in Ibs 9 5 0 9 Nm Thermistor 200 20 in Ibs 1 41 0 14 NM Thermostat Housing Ni Bleed Screw DEG 4 amp Washer Le Bolts 84 8 in lbs 9 5 0 9 Nm 70 10 in lbs 8 1 13 Nm cT POLARIS ENGINE S ENGINE EXPLODED VIEW ELECTRICAL COMPONENTS Fuel Injector Fuel Rail 24 in Ibs 2 7 Nm 216 24 5 See Chapter 4 for more information the EFI system T PGAR L 3 7 S ENGINE SPECIAL TOOLS PART NUMBE
55. will bubble and sputter as the air escapes Q Thermostat Housing Top Left Side of Engine amp 5 Squeeze the coolant lines by hand to help purge the system of air 6 Add Polaris Premium Antifreeze to the radiator if the level goes down 7 Tighten the bleed screw to 70 10 in lbs 8 1 13 Nm on the thermostat housing and properly install the radiator cap WARNING Be sure to install the radiator cap before shutting off the engine Coolant may spit out of the radiator 8 Stop the engine and let cool top off the radiator filler neck with coolant If you hear or see a glug at the filer neck or there is a dropping of the coolant level indicating that coolant has been pulled into the system Fill the surge tank only after you have completely filled the cooling system at the radiator filler neck cT POLARIS o 9 Repeatthis procedure if overheating still occurs If overheating occurs after repeating this procedure proceed to Procedure 2 PROCEDURE 2 1 Drive the machine onto a slight incline or use properly weight rated ramps Place the machine in Neutral and set the parking brake Block the rear wheels The radiator neck should be above the level of the top of the engine CAUTION Be sure the engine has cooled and there is no pressure built up in the cooling system before removing the radiator cap The coolant maybe hot and could cause severe injury or bums 2 Remove radiator cap an
Download Pdf Manuals
Related Search