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Engines and Cooling Systems - Les Entreprises Marc Latulippe

1. MODEL YEAR VEHICLE ENGINE MODEL NUMBER 600 Carbureted 121 Switchback 3273 6044 PU6F 600 Carbureted RMK 3274 6044 PU6F 2007 600 CFI 3206 6044 PU6H 700 CFI 121 3305 7044 PF7J 700 CFI RMK 3322 7044 PF7J 600 Carbureted 121 Switchback 3466 6044 PU6F 600 Carbureted RMK 3467 6044 PU6F 600 CFI 121 Switchback Touring 3468 6044 PU6H 600 CFI RMK 3469 6044 PU6H 2008 700 CFI 121 Switchback 53470 7044 07 700 CFI RMK 3471 7044 PU7J 800 CFI RMK 155 3489 8044 PU8E 800 CFI RMK 163 3741 8044 PU8E Early Build 2009 800 IQ 121 3804 8044 PU8E 550 IQ Shift EC55PM120 600 Carbureted Shift 121 53675 6044 600 4 Injector Touring 53677 6044 600 4 121 Dragon SP Switchback Dragon Switchback 53908 6044 2009 600 CFI 2 Injector Shift 136 Shift RMK 53747 6044 6 700 CFI RMK 53680 7044 7 800 CFI 121 Switchback 3683 8044 PN8E 800 CFI RMK w bulkhead cooler 53685 8044 800 CFI RMK Assault w o bulkhead cooler 53684 8044 550 IQ Shift EC55PM121 600 CFI 4 Injector Touring 53996 6044 600 CFI 4 Injector 121 Switchback S4176 6044 OP6H b t 600 CFI 4 Injector RMK 4177 6044 OP6H 600 CFI 2 2 Injector Widetrak 54203 6044 6 700 CFI RMK 54175 7044 7 800 121 Switchback RMK 144 155 4001 8044 OP8E 800 RMK Dragon 155 163 Assault w o bulkhead cooler 54002 8044 550 IQ Shift Shift 136 LXT EC55PM122 600 IQ Shift Shif
2. 5 18 ENGINE MOUNTING SYSTEMS RR REY Re REGE Ea A 5 19 550 IQ ENGINE 5 19 2007 IQ CARBURETED ENGINE 5 20 2007 IQ 600 CFI ENGINE 5 21 2008 2009 IQ CARBURETED ENGINE MOUNTING 5 22 2007 IQ 700 CFI 2010 2011 IQ CFI ENGINE 5 23 2008 2009 IQ CFI 2010 2011 IQ CFI TOURING 600 IQ WIDETRAK ENGINE MOUNTING5 24 ENGINE COMPONENT ASSEMBLIES ees 5 25 550 BLOWER HOUSING ASSEMBLY 5 25 550 CYLINDER 5 26 550 OIL PUMP ASSEMBLY shuca RR REVISE RE RE RR Rep 5 27 550 MAGNETO 5 5 28 550 CRANKCASE 5 29 550 PISTON AND CRANKSHAFT ASSEMBLY 5 30 600 CARBURETED CYLINDERS CYLINDER HEAD 5 31 600 HO CARBURETED RECOIL 5 32 600 CARBURETED PISTONS 5 34 600 CARBURETED CRANKCASE 5 36 600 HO CARBURETED OIL 5 38 600 700 CFI CYLIND
3. INTAKE BOOTS p REED STUFFERS U ALIGNMENT DOWELS jw amp 28 5 STATOR WIRE RETAINER A OIL INJECTION CHECK VALVE QTY 5 PTO SEAL MJ NEEDLE BEARINGS A S 9 5 9 FLYWHEEL KEY SN 532 PTO BEARINGS MAG BEARING 29 STATOR WIRE BEANE MAG SEAL X In mm Long Stud Height Exhaust side 4 13 105mm Small Stud Height Intake side 2 16 55mm ey A 9 Ft Lbs 12 Nm B 22 Ft Lbs 30 Nm C 10 Ft Lbs 13 Nm Apply Pipe Sealant gt TERRAIN DOMINATION 5 46 9922854 2007 2011 IQ Service Manual C POLARIS 2010 Polaris Sales Inc Engine and Cooling Systems Disassembly Assembly Process 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 7 Reinstall the crankshaft back into the lower crankcase using two new crankcase seals 8 Apply a
4. c clips 6 The piston ring locator pins and ring open ends always face the intake side of the engine 7 Always lubricate the piston assembly and cylinder with two stroke engine oil when installing the cylinder over the piston 1 Using a small flat blade screwdriver remove the clips Discard the c clips 2 Remove the piston pins using the piston pin puller PN 2870386 3 When replacing a piston always replace the rings c clips pins and needle bearings with new parts 4 Inspect the crankshaft as outlined in the Engine Inspection section within this chapter 5 Install the piston rings with the beveled edge facing 5 30 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Fastener Torque Note Flywheel and 58 72 1 105 crankshaft tapers Riywheel Nut 78 5 98 Nm to be clean and dry TERRAIN DOMIN gt POLARIS ATION Engine and Cooling Systems 600 HO Carbureted Cylinders Cylinder Head BLEED SCREW 1 Jn t 11 WASHERS THERMOSTAT HOUSING THERMOSTAT 9 HEAD COVER O RI CYLINDER HEAD O RINGS GASKET KNOCK SENSOR X ZZ 3 Cras KE CYLINDERS EN S THERMO SENSOR og AE YLINDER BASE GASKETS CYLINDER HEAD SEGAS bolt threads to remove any thread locking residue T 9 Carefully pull each cylinder upwards taking care not to drop t
5. 6 Subs to 2203319 53466 6044 6 53467 6044 6 2203319 EK 2202c 53675 6044 EK 2202b 5 34 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc gt POLARIS Engine and Cooling Systems Disassembly Assembly Process 1 To remove the pistons follow the process for removing the cylinder head and cylinders from the engine 2 To remove the crankshaft follow the process for disassembling the crankcase assembly 3 With the piston out of the cylinder remove one of the c clips and discard Never re use piston c clips 4 Push the piston pin out of the piston and upper rod bearings Inspect the pin for galling and abnormal wear Inspect the needle bearing by feel and replace as required 5 New pistons are supplied with new rings and a piston pin It is recommended that new needle bearings be installed as well 6 When installing a new piston insert one c clip into the piston making sure the open end is 180 opposite of the groove opening 7 Apply a liberal amount of Polaris two stroke engine oil to the needle bearings piston pin and piston assembly 8 Push the pin in to the piston then through the needle bearing Install the remaining c clip with the open end is 180 opposite of the groove opening NOTE Always use new cylinder base gaskets 9 Apply liberal amount of Polaris two stroke oil to the cylinder wall Align the piston ring g
6. 9922854 2007 2011 IQ Service Manual lt gt POLRHIS 2010 Polaris Sales Inc 5 65 Engine and Cooling Systems 2009 2011 IQ 121 Switchback Cooling System SURGE TANK X HOSE THROTTLE BODY OUT SURGE TANK gt gt To Throttle Body w HOSE TUNNEL COOLER TO SURGE TANK 2 9 HOSE SURGE TANK ENGINE 7 gt OSE ENGINE OUT TO TUNNEL COOLER THERMOSTAT OPEN Eng In N FRONT TUNNEL COOLER 6 NS x By Pass HOSE CYLINDER HEAD OUT TO FRONT COOLER HOSE FRONT COOLER OUT TO SURGE TANK TERRAIN DOMINATION 5 66 2010 Polaris Sales Inc 9922854 2007 2011 IQ Service Manual gt POLARIS Engine and Cooling Systems 800 RMK With Bulkhead Cooler SURGE TANK HOSE TUNNEL COOLER TO SURGE TANK CAP HOSE ENGINE OUT TO TUNNEL COOLER THERMOSTAT OPEN SQUEEZE CLAMPS HOSE THROTTLE BODY OUT TO SURGE TANK 0 A FRONT TUNNEL COOLER CA 2 FOAM PAD u HOSE CYLINDER HEAD OUT TO FRONT COOLER _ HOSE SURGE TANK TO ENGINE IN 2 HOSE FRONT CO LER OUT TO SURGE TANK A EAC 800 RMK Assault Without Bulkhead Cooler HOSE TUNNEL COOLER TO SURGE TANK SURGE TANK HOSE ENGINE OUT TO TUNNEL COOLER THERMOSTAT OPEN SQUEEZE CLAMPS HOSE THROTTLE BODY OUT TO SURGE TANK FRONT TUNNEL CLOSEOFF PANEL HOSE SURGE TANK TO ENGINE IN 7
7. Compare Plastigage width to interference fit specification _ LA mm Bearing Interference Fit Carbureted 001 002 026 051mm CFI 0014 0024 061mm Main Bearing Clean crankshaft thoroughly and oil main and connecting rod bearings with Polaris engine oil Carefully check each main bearing on the crankshaft Due to extremely close tolerances the bearings must be inspected visually and by feel Look for signs of discoloration scoring or galling Turn the outer race of each bearing The bearings should turn smoothly and quietly The inner race of each bearing should fit tightly on the crankshaft The outer race should be firm with minimal side to side movement and no detectable up and down movement Replace any loose or rough bearings TERRAIN DOMINATION gt POLARIS Connecting Rod Lower Bearing Measure connecting rod big end side clearance with a feeler gauge on both sides of the connecting rod The side clearance on either side of the connecting rod cannot exceed the connecting rod side clearance specification The difference between the two clearance measurements cannot exceed the maximum clearance differential specification n mm Connecting Rod Side Clearance 0114 0295 289 749mm Maximum Clearance Differential 002 051mm Rotate the connecting rod on the crankshaft and feel for any rough spots Check radial end play in rod
8. It is sometimes necessary to check multi cylinder crankshafts to verify that one cylinder has not been forced out of position relative to the other cylinder Some causes for a out of index crankshaft include but are not limited to the following Hydrolock from water or fuel Impact to drive clutch from object or accident Abrupt piston or other mechanical failure Engine lock up due to drive belt failure Symptoms of an out of index crankshaft can include but are not limited to the following Difficulty calibrating carburetor repetitive plug fouling on one cylinder with no other cause Unexplained piston failure on one cylinder i e severe detonation broken ring lands etc Excessive vibration of engine back firing etc Rough idle poor top speed Checking Crankshaft Index 1 Remove the drive belt and drive clutch 2 Securely fasten a large degree wheel on the flywheel or PTO end of the crankshaft Make sure that it is 100 ATDC Crankshaft center line 5 12 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc mounted concentrically with the crankshaft center line 3 With a section of wire wire coat hanger anchor it to a convenient spot Bend one end at the outer perimeter of the degree wheel as shown below 4 Install a dial indicator into the magneto end cylinder spark plug hole The ignition timing is referenced by the magneto end 5 Locate TDC as accuratel
9. THROTTLE BODY OUT TO SURGE TANK CFI ONLY PS e Q ae HOSE ENGINE OUT TO TUNNEL COOLING SYSTEM THERMOSTAT OPEN HOSE BYPASS LH FOOTBOARD COOLER TO RADIATOR e FRONT COOLER HOSE SURGE TANK AY TO ENGINE IN Z i CR 3 g gt HOSE RADIATOR TO SURGE TANK gt gt RADIATOR 5 63 TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual gt POLARIS 2010 Polaris Sales Inc Engine and Cooling Systems 2007 2010 IQ 600 RMK 700 RMK Cooling System CAP SURGE TANK HOSE THROTTLE BODY OUT TO SURGE TANK CFI ONLY HOSE FRONT COOLER OUT TO SURGE TANK HOSE TUNNEL COOLER TO SURGE TANK HOSE ENGINE OUT TO TUNNEL COOLER THERMOSTAT OPEN Iu CLAMPS HOSE SURGE TANK TO ENGINE IN FOAM PAD HOSE CYLINDER HEAD OUT TO FRONT COOLER x FRONT TUNNEL COOLER 2 GEAR CLAMP 5 64 TERRAIN DOMINATION gt POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Engine and Cooling Systems 2008 IQ 121 Switchback Cooling System ji RH PERIMETER COOLER g CROSSOVER HOSE HOSE TUNNEL COOLERS OUT TO SURGE TAN HOSE FRT COOLER OUT TO SURGE TANK HOSE BYPASS TO FRT COOLER SURGE TANK CAP HOSE ENGINE OUT TO TUNNEL COOLER HOSE SURGE TANK OUT TO ENGINE IN THERMOSTAT OPEN TERRAIN DOMINATION
10. 242 EMEN mead Bypass 7 Ft Lbs 9 5 Nm N A itting 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 N A Loctite 242 Apply Loctite EV Bellows Nut 16 Ft Lbs 22 Nm Seis ists threads Cylinder Base Nuts 37 Ft Lbs 50 Nm N A 37 Ft Lbs 50 Nm 25 29 Ft Lbs Cylinder Bolts N A 42 Ft Lbs 57 Nm N A PTO Crank Seal Guard N A 12 Ft Lbs 16 Nm N A us Intake Boots 9 Ft Lbs 12 Nm 5 Ft Lbs 7 Nm Exhaust Manifold 22 Ft Lbs 30 Nm 18 Ft Lbs 24 Nm Oil Pump 7 Ft Lbs 9 5 Nm 48 72 In Lbs Water Pump Cover 9 Ft Lbs 12 Nm N A Recoil Housing 9 Ft Lbs 12 Nm Hand Tight Recoil Hub 9 Ft Lbs 12 Nm Flywheel Nut 90 Ft Lbs 122 Nm 58 72 Ft Lbs Loctite 242 Magneto 12 Ft Lbs 16 Nm 5 Ft Lbs 7 Nm 5 6 5 Ft Lbs Loctite 242 Crankcase 9 Ft Lbs 12 Nm M6 Apply Loctite 242 ALL 15 18 Ft Lbs M8 22 Ft Lbs 30 Nm 22 Ft Lbs 30 Nm 78 98 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 MA Fuel Rail 9 Ft Lbs 12 Nm N A Crankcase Drain Plugs 60 In Lbs 7 Nm AM SS Air Intake Gear Clamps 11 In Lbs 1 2 Nm 5 2 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc TERRAIN DOMINATION gt POLARIS Engine and Cooling Systems Vehicle Engine Matrix
11. 35 30 85 117 151 Upper RE 0042 006 25 45 S3322 7044 PF7J 109 163 TM 014 020 35 50 5 4 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc TERRAIN DOMINATION gt POLARIS Engine and Cooling Systems 2008 2010 800 Engines PISTON TO ENGINE MODEL 22 HEAD SQUISH CYLINDER ae END NUMBER INCHES MM CLEARANCE elles M Tum INCHES MM 2008 800 S3489 8044 PU8E S3741 8044 PUBE S3804 8044 PUBE 0047 0057 2009 800 120 146 53683 8044 362 378 221 E Service Parts z 7 p 36 1 34 S3684 8044 PN8E 0047 006 53685 8044 8 120 153 2010 800 54001 8044 54002 8044 NOTE 2008 2009 800 engines change to the 2010 specifications after completing Service Bulletins 5 09 08 or S 09 09 Piston Cylinder 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 5 5 9922854 2007 2011 IQ Service Manual lt gt POLRHIS 2010 Polaris Sales Inc Engine and Cooling Systems Component Torque Sequences
12. 8044 800 CFI Cylinder Head Cylinder Pistons Disassembly and Assembly 1 Remove the coolant from the engine using a siphon wet dry vac or drain pan 8 If only the cylinder is going to be removed remove the fuel rail from the upper fuel injectors See Fuel Rail and Injector Removal Installation on page 4 38 NOTE Leave the exhaust Y pipe attached to the cylinder assembly Remove Y pipe after removing cylinder from crankcase 9 10 11 12 13 14 15 16 17 18 Loosen all then remove the cylinder bolts Clean the bolt threads to remove any thread locking residue Carefully pull the cylinder upwards taking care not to drop the pistons and rods abruptly against the crankcase Remove the cylinder base gasket Use a gasket scraper to clean the gasket residue from the crankcase and cylinder base Inspect the cylinder walls Nicasil cylinders can only be lightly honed using a 320 grit stone Damage that cannot be removed with a light hone requires cylinder replacement or re chroming Inspect the crankcase and cylinder mating surfaces for warping The assembly process is the reverse of disassembly 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 Always refresh the cylinder crosshatch pattern using a 320 grit stone See Cylinder Honing on page 5 1
13. Pin Puller PS 47055 Adapter 800 CFI Engines 2870386 Piston Pin Puller 2871445 Pin Puller Adapter Use with 2870386 Removes tabbed rubber engine 2871989 Engine Mount Socket mounte 2872389 Water Pump Seal Used to install water pump seal Installation Tool on all 600 700 800 engines Install c clips on all 600 700 2872401 A 20mm C Clip Tool engines 2872622A 22mm C Clip Tool Install c clips on all 800 engines Use to loosen or tighten oil pump PS 49001 Oil Cable Wrenches cable jam nuts 2870630 pn Powerga Timing Check ignition timing 14mm Compression 2870852 Gauge PU 45149 Hose Pincher PU 45419 Strap Wrench Secure drive clutch or flywheel Use to inspect cylinder bore PU 45423 Telescoping Gauge Set diameter Use to measure run out piston PU 45424 Dial Indicator Set degrees to TDC etc PV 39776 Electronic Digital Caliper PU 45433 Seal Pick Set PU 45431 Depth Micrometer Set PV 34673 Precision Straight Edge PV 43554 V Block Set PV 3009 75 100mm Micrometer Use to measure piston diameter etc TERRAIN DOMINATION gt POLARIS ENGINE INSPECTIONS Cylinder Head Inspection Using a precision straight edge and a feeler gauge to in spect cylinder head for warping Replace head if warping exceeds 006 015mm B In mm Oylinder Head Warp Limit 006 015mm 5 7 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Engine
14. and Cooling Systems 2007 700 Dragon IQ Cooling System HOSE THROTTLE BODY OUT TO SURGE TANK CFI ONLY REAR TUNNEL COOLER SURGE BOTTLE sul 2 dm lt gt i 2 8 HOSE ENGINE OUT FRONT COOLER 0 THERMOSTAT OPEN P 25 d i 15 9 HOSE d TO LH PERIMETER COOLER TO SURGE BOTTLE HOSE SURGE BOTTLE OUT TO ENGINE IN HOSE BYPASS OUT TO TUNNEL COOLING SYSTEM THERMOSTAT CLOSED OPEN TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual lt gt POLRHIS 2010 Polaris Sales Inc 5 61 Engine and Cooling Systems 2007 600 IQ 121 Switchback LX 2008 CFI LX Cooling System SURGE BOTTLE 5 amp HOSE THROTTLE BODY 2 RH PERIMETER COOLER OUT TO SURGE TANK 0 CFI ONLY Va REAR COOLER REVERSED ON S B Z LH PERIMETER COOLER enc h HOSE BYPASS TO RADIATOR HOSE SURGE BOTTLE TO ENGINE IN 9 Hose ENGINE OUT TO TUNNEL COOLING SYSTEM THERMOSTAT OPEN By pass FRONT COOLER 6 RADIATOR SURGE BOTTLE RADIATOR 5 62 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc gt POLARIS Engine and Cooling Systems 2007 2011 IQ Touring Cooling System o REAR COOLER gt SURGE TANK RH FOOTBOARD COOLER HOSE
15. bore size and finish Cleaning 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 Pay close attention to areas where the cylinder sleeve meets the aluminum casting transfer port area Use electrical contact cleaner if necessary to clean these areas Rinse thoroughly dry with compressed air and oil the bore immediately with Polaris Premium 2 Cycle Lubricant NOTE Always check piston to cylinder clearance and piston ring installed gap after honing or boring is complete 5 13 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Engine and Cooling Systems Crankshaft Truing Lubricate the bearings and clamp the crankshaft securely in the holding fixture If truing the crankshaft requires striking with a hammer always be sure to re check previously straightened areas to verify truing Refer to the illustrations below Use Crankshaft alignment kit PN 2870569 NOTE The rod pin position in relation to the dial indicator tells you what action straighten the shaft is required to Truing Examples To correct a situation like this Strike the shaft at point A with a brass hammer HIGH 004 1 mm HIGH 004 1mm AA SUPPORT CRANKSHAFT AT THESE TWO BEARINGS To correct a situation like the one shown in this Squeeze the cranksha
16. engine compartment and line up the engine mount studs with the engine straps on the engine NOTE Make sure that all hoses lines and wires are not pinched or interfere with installation 14 Connect all the coolant hoses 15 Place panduit straps in the locations shown 16 If applicable place the coolant hose from the throttle bodies to the coolant bottle imm 17 Secure the hose clamp over all coolant hose and fittings TERRAIN DOMINATION gt POLARIS 18 Place the engine mount washers and fasteners 8 21 onto the engine mount studs Torque to specification Engine and Cooling Systems Adjust the rear torque stop so that you have a clearance of 010 030 25 75mm from the face of the torque stop to the surface of the engine lt In mm Rear Torque Stop Clearance 010 030 25 75mm gt T Engine Mount Fasteners 28 ft lb 37 9 N m 22 23 NOTE If a new torque stop is installed install it so that the nub is touching the engine This nub is 030 75 long Adjust the engine isolator limiter if equipped so the stop is bottomed out on the brace Stop touching base Install the front torque stop assembly and torque the plate fasteners to specification 20 Apply Blue Loctite to the rear fasteners install all Front Torque Stop Fasteners 28 ft lb 37 9 N m ey T the rear torque sto
17. housing 4 Inspect all components for signs of abnormal wear and tear Replace components as required If replacing the rope tie a small square knot at one end Push the knot firmly into the pocket on the reel 5 f the reel recoil spring was removed during disassembly install the spring by spiraling the spring counterclockwise toward the center of the housing 6 Lubricate the center shaft and spring with Premium grease TERRAIN DOMINATION POLARIS 7 Wind the rope counterclockwise around the pulley as viewed from the ratchet side of the reel 8 Pass the end of the rope through the hole in the housing If the rope guide was removed from the housing reinstall it before attaching the rope handle 9 Slide the reel down the center shaft and into the housing making sure the recoil spring re engages the reel tab 10 Install the return spring and ratchet into the reel face The return spring leg fits in the notch on the ratchet and holds the ratchet in retracted 11 Install friction spring with one leg inserted in the bottom hole on the ratchet 12 Apply Loctite 242 and install screw and washer and torque to specification 13 Pull rope out to its full extension and align pulley notch with rope hole in housing 14 Using a needle nose pliers or hooked wire pull a loop of rope through the notch in the reel 15 Prevent the rope from being retracted by tieing a knot in the rope on the outside of the hou
18. 010 Polaris Sales Inc gt POLARIS Engine and Cooling Systems Disassembly Assembly Process Piston Matrix 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 Engine Model Piston PN Piston ID 13 The assembly process is the reverse of disassembly S3206 6044 PF6G 14 Always use new gaskets and o rings during S3468 6044 PU6H 2203319 EK 22202c assembly Liberally coat the inside of each cylinder S 3469 6044 PU6H and the outside of each piston with Polaris two stroke 1 7 engine oil SoS a 292298 15 Always refresh the cylinder crosshatch pattern using 2203312 a320 grit stone See Cylinder Honing on page 5 13 53322 7044 7 EK 2486a Subs to 2203512 16 When installing a piston into a cylinder verify each S3470 7044 PU7J 2203707 3050 00 piston ring opening is located at each piston ring locating pin Squeeze the top ring then carefully slide S9471 0 UT 2203606 the cylinder over the compressed ring Do the same 53680 7044 7 2975 01 ith the b S4175 7044 OP7J Single Ring with the bottom ring 17 Follow the torque specifications torque 53677 6044 sequences located at beginning of chapter when 22 Subs to 2204122 3090 00 tightening fasteners 3996 6044 OP6H S4176 6044 OP6H 54177 6044 2204122 3090 0
19. 1 54216 6044 4218 6044 OO6H 54203 6044 S4219 6044 OO6N 2204152 3222 00 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 cylinders are going to be removed remove the fuel rail from the upper fuel injectors See Fuel Rail and Injector Removal Installation on page 4 38 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 TERRAIN DOMINATION gt POLARIS 5 41 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Engine and Cooling Systems 800 CFI Cylinder Head Cy
20. 3 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 Follow the torque specifications torque sequences located at beginning of chapter when tightening fasteners 5 43 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 lt gt POLARIS Engine and Cooling Systems 600 700 800 CFI Recoil Stator Assembly WIRE RETAINER FLYWHEEL NUT 7 wey A 54 WS FLYWHEEL RATCHET GUIDE B Ses REEL w ROPE RETURN SPRING A 9 Ft Lbs 12 Nm B 2007 2010 Engines 9 Ft Lbs 12 3 Nm Apply Loctite 242 2011 Engines 15 Ft Lbs 20Nm Apply Loctite 242 C 90 Ft Lbs 122 Nm Apply Loctite 242 D 12 Ft Lbs 16 Apply Loctite 242 5 44 TERRAIN DOMINATION 9922854 2007 2011 IQ Se
21. 4 GEAR CLAMP TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual lt gt POLRHIS 2010 Polaris Sales Inc 5 67 Engine and Cooling Systems 600 Widetrak Bypass Circuit Cy SURGE TANK HOSE BYPASS OUT TO BRAKE sf CAP HOSE THROTTLE BODY OUT TO SURGE TANK BE HOSE SURGE TANK TO ENGINE IN RADIATOR AIR BLEED SCREW 600 Widetrak Tunnel Circuit NOTE TUNNEL CIRCUIT ONLY ACTIVE WHEN THERMOSTAT IS OPEN CROSSOVER HOSE SQUEEZE CLAMPS gt FRONT TUNNEL COOLER HOSE ENGINE OUT TO FRONT TUNNEL COOLER TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual gt POLARIS 2010 Polaris Sales Inc 5 68 Engine and Cooling Systems EXHAUST SYSTEMS Assembly View Typical 2 ZINC PLATED YELLOW SPRINGS 2 2 SILENCER pe V EXHAUST PIPE ZINC PLATED YELLOW SPRINGS BUMPER SHIM COL COW 23 MANIFOLD Ss GASKETS p MN TAN gt v 5 1 lt lt C Ve gt V B GASKET e E lt STAINLESS STEEL GRAY SPRINGS ey T A EGT Sensor 32 Ft Lbs 44 Nm B Exhaust Manifold Fasteners 22 Ft Lbs 30 Nm NOTE Always use the stainless steel gray springs to connect the exhaust pipe to the exhaust manifold TERRAIN DOMINATION gt POLARIS 9922854 2007 2011 IQ Service Manual 5 69 2010 Polaris
22. CFI Crankcase Torque Pattern Cylinder Head Torque Pattern Domestic All Except 800 5 s eo Q GR qu SIE CEN 7 GG w ro 600 HO Carbureted Crankcase Torque Pattern Cylinder Head Torque Pattern Domestic 800 5 e ww Er 59 9 MAG PTO Cylinder Torque Pattern Except Monoblock MAG PTO 550 Engine Cylinder Head Torque Sequence 4 5 7 MAG 1 e AO X PTO MAG o Cylinder Torque Pattern Monobl 9 550 Crankcase Torque Pattern 5 3 CONS 1 9 1 CFI Recoil Cover PTO MAG 5 7 TERRAIN DOMINATION Gn 5 6 9922854 2007 2011 IQ Service Manual lt gt POLARIS 2010 Polaris Sales Inc Engine and Cooling Systems TOOLS SPECIAL Special Tools Engine Special Tools Engine PART NUMBER DESCRIPTION NOTE Use to re surface cylinder walls 2870303 A Ammco Hone Kit when installing new piston and or rings Provides better crosshatch 28 0598 Mona Ol pattern when honing cylinders Use re surface NiCaSil lined PU 49876 Ammco 320 Grit Stone big bore cylinders Supports piston when installing 2870390 Piston Support Block pin and c clips 2871043 A Flywheel Puller PU 45255 22mm Piston Pin Puller 800 CFI Engines Offset Piston
23. ER HEAD CYLINDERS PISTONS 5 40 800 CFI CYLINDER HEAD CYLINDER PISTONS 5 42 800 CFI CYLINDER HEAD CYLINDER PISTONS COMPATIBILITY 5 43 800 CFI CYLINDER HEAD CYLINDER PISTONS DISASSEMBLY AND ASSEMBLY 5 43 600 700 800 CFI RECOIL STATOR ASSEMBLY 5 44 600 700 CFI CRANKCASE CRANKSHAFT ASSEMBLY 5 46 800 CFI 5 48 600 700 800 WATER OIL PUMP ASSEMBLY 5 50 600 700 800 CFI OIL HOSE 5 52 ENGINE REMOVAL TYPICAL 5 53 ENGINE INSTALLATION TYPICAL 5 56 GOOLING SYSTEMS cx taneous putet dee Gad oe OX tes bik ex d eae WES 5 59 EXHAUST SYSTEMS ode porn EX Tere e mii PR EOS 5 69 ASSEMBLY VIEW TYPICAL suse RII eee 5 69 TERRAIN DOMINATION gt POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 5 1 Engine and Cooling Systems ENGINE SPECIFICATIONS Fastener Torque Guide COMPONENT 600 700 CFI 800 CFI 550 FUJI Spark Plug 18 Ft Los 24 Nm Apply Nyogel Head Cover 25 Ft Lbs 34 Nm 17 20 Ft Lbs Loctite
24. Engine and Cooling Systems CHAPTER 5 Engine and Cooling Systems ENGINE SPEGIFIGATIONS dub Eie ke ea ev re die en 5 2 FASTENER TORQUE 2 5 2 VEHICLE ENGINE MATRIX 5 3 ENGINE SPECIFICATIONS 1 5 4 PISTON CYLINDER SPECIFICATIONS 5 5 ENGINE SERVICE SPECIFICATIONS ALL ENGINES 5 5 COMPONENT TORQUE SEQUENCES 1 5 6 SPECIAL TOOLS wos eee se wreath Poet buses aM een wee 5 7 SPECIAL TOOLS ENGINE u aqasha uw gu umaq gua ai 5 7 ENGINE INSPECTIONS 555 P EXE LE xa eed ded tas 5 7 CARBURETED RECOIL ASSEMBLY 5 16 ROPE REMOVAL AND 5 16 GE RECOILASSEMBIEY huyu Cau halus FC LR n pt Apres 5 17 ROPE REMOVAL AND 5 17 EXHAUST VALVE MAINTENANCE xta ie pn ru RF 5 18 EXHAUST ASSEMBLY 5 18 EXHAUST VALVE 5 5 18 EXHAUST VALVE 5 18 EXHAUST VALVE SPRINGS
25. FF RR A N DOMINATION 5 52 9922854 2007 2011 IQ Service Manual gt POLARIS 2010 Polaris Sales Inc Engine Removal Typical NOTE Inspect all parts for wear or damage during disassembly Replace all seals o rings and gaskets with Genuine Pure Polaris parts during assembly NOTE The following removal and installation process involves a CFI engine Carbureted engines do not use throttle bodies or the electrical components housed in the drive clutch cover electrical center 1 Open the hood and remove the side panels 2 Disconnect the battery ground cable from the battery if equipped 3 If equipped unplug exhaust temperature sensor remove the exhaust system 4 Remove the spark plug leads from the spark plugs 5 f equipped remove the belt cover electrical center On CFI models diseannect the intake air sensor 6 located on the MAG side of the airbox E 7 CFI models remove the return fuel line P holder located on the MAG side of the airbox TERRAIN DOMINATION POLARIS Disconnect the regulator rectifier connections Disconnect the ignition coil connections and EV solenoid from the ECU harness on CFI models 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Engine and Cooling Systems 8 On CFI models separate the fuel filter from the filter clip that is on the MAG side of the airbox 9 Remove the airbox by removing the gear clamps
26. Flush out the crankcase 6 Reinstall the crankshaft back into the lower crankcase using two new crankcase seals 7 Apply a thin bead of Three Bond 1217H to the lower crankcase mating surface Install the upper crankcase 8 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 TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual lt gt POLRHIS 2010 Polaris Sales Inc 5 37 Engine and Cooling Systems 600 HO Carbureted Water Oil Pump SEAL 0 WASHER 0 WATER PUMP COVER GASKET MECHANICAL SEAL B WATER PUMP COVER WASHER NUT GASKET 0 OIL PUMP CROSS SHAFT WASHER ey T A 7 Ft Lbs 9 5 Nm B 10 Ft Lbs 13 Nm C 9 Ft Lbs 12 Nm TERRAIN DOMINATION 5 38 9922854 2007 2011 IQ Service Manual gt POLARIS 2010 Polaris Sales Inc Engine and Cooling Systems Disassembly Assembly Process IMPORTANT Use the mechanical seal installation tool to install the water pump seal PN 2872010 1 Remove the coolant from the engine using a siphon wet dry vac or a drain pan 2 Remove the airbox exhaust pipe and resonator Remove the hose connected to the water pump cover 3 access the impeller and mechanical seal remove the water pump cover Discard the water pump cover gasket 4 Remove the imp
27. LUE connector goes to the PTO coil lower TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual lt POLARIS 2010 Polaris Sales Inc 5 58 37 Install the electrical center belt holder over the electrical center by aligning the rear buttons to the rear of the clutch cover and installing the two fasteners KUU 7 38 Install the Nylock nuts and two T40 Torx bolts to the front and the two T40 to the rear of the LH and RH chassis brace and install the braces NOTE Install the long bolts and the spacer on the front portion of the bar before inserting it into the mounting area 39 Replace the nosepan plugs were removed to access the front chassis brace fasteners 40 Route the recoil rope through the eyelet on the chassis brace and secure handle once past the console 41 Install the exhaust system 42 Add coolant and bleed system See Cooling System Bleeding on page 3 9 43 Premix the first tank of fuel See Fuel Oil Premix Ratios on page 2 12 44 Test run the unit and clear any codes with Digital Wrench 45 After test running check drive and driven clutch torque TERRAIN DOMINATION POLARIS Engine and Cooling Systems COOLING SYSTEMS Thermostat Replacement BLEED SCREW WASHER HOUSING COVER THERMOSTAT A CAUTION Allow engine to cool completely before working with the engine cooling system Engine coolant can be under press
28. Sales Inc Engine and Cooling Systems NOTES TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc C P amp SLARIS 5 70
29. and Cooling Systems 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 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 Middle Bottom s In mm Taper Limit 002 051mm Out of Round Limit 002 051mm 5 8 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Crankshaft Runout Inspection x lt x th d SUPPORT SHAFT AT TWO ARROWS 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 f the runout deflection exceeds the maximum specification crankshaft trueing may correct the deflection TERRAIN DOMINATION gt POLARIS Engine and Cooling Sy
30. aps around the piston locating pins Compress the upper ring then carefully slide the cylinder down over the ring 10 Compress the lower ring then slide the cylinder down over the ring TERRAIN DOMINATION gt POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 5 35 Engine and Cooling Systems 600 HO Carbureted Crankcase O amp CYLINDER STUDS Q a SASS 2 par INTAKE BOOTS REED STUFFERS Aas DEFA W w REED ASSEMBLIES OIL INJECTION CHECK VALVES e T 9 Ft Lbs 12 Nm A B M8 22 Ft Lbs 30 Nm Apply Loctite 242 C M6 9 Ft Lbs 12 Nm Apply Loctite 242 gn In mm Long Studs Height Exhaust side 3 66 93mm Small Stud Height Intake side 2 16 55mm TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual gt POLARIS 2010 Polaris Sales Inc 5 36 Engine and Cooling Systems Disassembly Assembly Process 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 and reed assemblies Discard any seals or gaskets 4 Remove the crankcase fasteners then carefully pry apart the crankcase halves Discard the PTO and MAG crankshaft seals 5 Clean the two crankcase mating surfaces with carburetor cleaner and a gasket remover
31. ase Remove the crankcase fasteners Thoroughly clean the fasteners to remove any locking agents Discard both crankshaft seals Thoroughly clean the two crankcase mating surfaces and the inner crankcases Inspect for cracks Verify both crankcase drain screws are securely installed Apply a thin bead of Three Bond 1217H to both crankcase mating surfaces Lubricate the oil pump drive gear with two stroke engine oil and install into crankcase gt POLARIS Install crankshaft and two new crankcase seals Verify seal lips face the inside of the engine Ensure crankshaft retaining ring and bearing locating pins are seated correctly before installing upper crankcase Torque crankcase fasteners to specified torque and sequence outlined at beginning of chapter Fastener Torque Note Apply Three Bond 15 18 1 105 1217H to 20 25 Nm crankcase mating surfaces 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 5 29 Engine and Cooling Systems 550 Piston and Crankshaft Assembly C CLIP Qn PISTON THRUST WASHER BEARING S PISTON RINGS gt a WASHER PISTON PIN ios NEEDLE BEARING NEEDLE BEARING CONNECTING ROD PIN WASHER FLYWHEEL KEY MAG CRANKWEB m P td 2 WASHER BEARING 0 FLYWHEEL NUT Disassembly Assembly Process upwards CAUTION Wear eye protection when removing or installing piston
32. asket is installed on the oil pump before taking measurement TERRAIN DOMINATION 4 Subtract measurement B from A to determine the total 5 Measure the total thickness of the original shims Engine and Cooling Systems MEASUREMENT B bushing end play Subtract this number from the number obtained in step 4 6 Add or subtract shims to obtain the specified oil pump bushing end play i Ain mm Oil Pump Oil Pump Bushing End Play 008 016 203 406mm gt Available Shims 30803671 006 15mm 30803672 012 30mm 30803673 024 60mm 5 15 9922854 2007 2011 IQ Service Manual lt gt POLRHIS 2010 Polaris Sales Inc Engine and Cooling Systems CARBURETED RECOIL ASSEMBLY Rope Removal and Installation TAB ENGAGES INSIDE PULLEY FRICTION PLATE Recoil spring under high tension Always wear eye protection when working with recoil housing components 1 With the recoil housing removed from the engine un tie any knots handle in the recoil rope and allow the pulley to slowly unwind 2 Remove the nut friction plate friction spring ratchet and ratchet spring from the pulley 3 Lift the pulley straight out of the housing making sure the spring is no longer connected to the backside of the pulley NOTE If all of the recoil spring tension was removed the spring should stay inside the housing when
33. base housing with parts 7041704 05 Yellow 1 734 solvent and a stiff bristle brush Ensure transfer ports 7041704 06 White 1 537 are clean and no carbon residue remains inside the chambers 5 18 TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc POLARIS Engine and Cooling Systems ENGINE MOUNTING SYSTEMS 550 IQ Engine Mounting TORQUE STOP od OA A A I e ENGINE Ae i REAR MOUNT PLATE ENGINE MOUNT ENGINE MOUNT As TORQUE STOP BRACKET Q SUPPORT A MOUNT PLATE ENGINE MOUNT PLATE zi Sa ENGINE MOUNT Me 28 Ft Lbs 38 Nm B 15 Ft Lbs 20 Nm C 45 Ft Lbs 61 Nm NOTE Use an engine mount socket PN 2871989 to remove the engine mounts from the bulkhead TERRAIN DOMINATION gt POLARIS 9922854 2007 2011 IQ Service Manual 5 1 9 2010 Polaris Sales Inc Engine and Cooling Systems 2007 IQ Carbureted Engine Mounting TORQUE STOP amp ENGINE MOUNT ISOLATOR CLINCH PLATE ey T A 28 Ft Lbs 38 Nm B 15 Ft Lbs 20 Nm C 45 Ft Lbs 61 Nm NOTE Use an engine mount socket PN 2871989 to remove the engine mounts from the bulkhead TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual gt POLARIS 2010 Polaris Sales Inc 5 20 Engine and Cooling Systems 2007 IQ 600 CFI Engine M
34. be reduced A crosshatch angle which is too shallow will cause ring vi bration poor sealing and overheating of the rings due to blow by and reduced contact with the cylinder wall Ser vice life of the pistons and rings will be greatly reduced NOTE A Nicasil cylinder can be lightly honed with a 320 grit stone hone but can not be oversized EXAMPLE OF A CROSS HATCH PATTERN Honing Tools The following tools are recommended Ammco 3950 Hone Kit SPX PN 2870303 A commercially available Ammco 3956 Honing Stones 320 grit Oversize SPX PN PU 49876 Honing Oil SPX PN 2870588 Commercially Available TERRAIN DOMINATION POLARIS Honing Procedure 1 Wash the cylinder with cleaning solvent Clamp the cylinder in a soft jawed vise by the cylinder studs 3 Place hone in cylinder and tighten stone adjusting knob until stone contacts the cylinder walls DO NOT OVERTIGHTEN 4 Apply honing oil to the stones and cylinder walls Wet honing removes more material faster and leaves a more distinct pattern in the bore 5 Using a 1 2 13 mm drill motor rotating at a speed of 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 to prevent edge loading and always bring the stone approximately 1 2 1 2 cm beyond the bore at the end of each stroke 6 Release the hone at regular intervals to inspect
35. by supporting rod against one thrust washer and alternately applying up and down pressure Replace bearing pin and thrust washers if side clearance is excessive or if there is any up and down movement detectable in the big end bearing TERRAIN DOMINATION gt POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Engine and Cooling Systems Piston Needle Bearing 1 Clean the end of the connecting rod and inspect inner bore with a magnifying glass Look for any surface irregularities including pitting wear or dents 2 Runafingernail around the inside of the rod and check for rough spots galling or wear 3 Oil and install needle bearing and pin in connecting rod 4 Rotate pin slowly and check for rough spots or any resistance to movement 5 Slide pin back and forth through bearing while rotating and check for rough spots 6 With pin and bearing centered in rod twist ends back and forth in all directions to check for excessive axial play 7 Pull up and down evenly on both ends of pin to check for radial play 8 Replace pin and bearing if there is any resistance to rotation or excessive axial or radial movement If play or roughness is evident with a new pin and bearing replace the connecting rod 5 11 Engine and Cooling Systems Crankshaft Index Polaris crankshafts are pressed together The connecting rod journal center lines are indexed 180 apart from each other
36. e attention the recoil rope can remained attached to the handle If recoil component work is desired reference the Recoil Assembly section See Carbureted Recoil Assembly on page 5 16 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 Clean the crankshaft and flywheel tapers with a solvent such as clutch cleaner 10 Assembly is reverse of disassembly Reference the fastener torque specifications at the beginning of the chapter 11 Do not use an impact wrench to install the flywheel nut TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual lt gt POLRHIS 2010 Polaris Sales Inc 5 33 Engine and Cooling Systems 600 HO Carbureted Pistons Crankshaft PISTON RINGS PISTON PIN Piston Matrix Engine Model Piston PN Piston ID 3273 6044 PF6F 2202258 53274 6044
37. e the recoil fan housing from the engine The Secure fasteners recoil pulley is located inside the housing Recoil Fan after allcovers are 4 Reference RECOIL PULLEY section for recoil Housings in place and disassembly assembly information snapped together 5 The fan flywheel and stator must be removed to TERRAIN DOMINATION 5 25 9922854 2007 2011 IQ Service Manual lt gt POLRHIS 2010 Polaris Sales Inc Engine and Cooling Systems 550 Cylinder Assembly CYLINDER INTAKE BOOT SCREW CLAMP 5 REED REED CAGE ASSEMBLY CYLINDER HEAD EXHAUST GASKET Disassembly Assembly Process 1 6 5 26 Remove the carburetors intake boots exhaust manifold and blower housing from the engine assembly Discard all used gaskets Remove cylinder head screws Remove cylinder head then discard gasket Note the orientation of the head for use during assembly Remove the cylinder base nuts Lift the cylinder off of the crankcase Discard the cylinder base gasket Remove reed valve cage and inspect for abnormal wear and damage Replace reed pedal and or cage if damage or wear is found During assembly the reed valve assembly is installed under the cylinder base gasket Install the base gasket with the sealing strip facing upwards Lubricate cylinder walls and piston with two stroke engine oil when installing each cylinder 9922854 2007 2011 IQ Se
38. ead 15 Follow the torque specifications and torque locking residue sequences located at beginning of chapter when 6 Discard the head cover and cylinder head o rings tightening fasteners 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 Loosen all then remove the cylinder bolts Clean the TERRAIN DOMINATION gt POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 5 31 Engine and Cooling Systems 600 HO Carbureted Recoil Magneto RECOIL HUB FRICTION PLATE FRICTION SPRING RECOIL HANDLE RETURN SPRING 5 5 9 eO S SER NN 6 atts 254 e We LASS Ae gt ROPE REEL Es S S gt gt Z B 2 hr gt RATCHET NAD AY LDF 2 me di lt lt S d A MAGNETO STATOR d N Ke ZJ ROPE GUIDE x p SPRING C S Js Y amp de FLYWHEEL FLYWHEEL NUT RECOIL HOUSING e T A 9 Ft Lbs 12 Nm B 5 Ft Lbs 7 Nm Apply Loctite 242 Stator C 90 Ft Lbs 122 Nm Apply Loctite 242 5 32 TERRAIN DOMINATION 2007 2011 IQ Service Manual 2010 Polaris Sales Inc gt POLARIS Engine and Cooling Systems Disassembly Assembly Process Remove the exhaust pipe and resonator 2 If the recoil assembly does not requir
39. ed wire pull a loop of rope through the notch in the pulley 15 Prevent the rope from being retracted by tieing a knot in the rope on the outside of the housing at the rope guide hole 16 Wind the recoil pulley counterclockwise until the spring begins to bind Unwind the pulley clockwise two revolutions 17 Pull on the rope to disengage it from the notch in the pulley Un tie the knot in the rope and allow it to retract into the housing 18 Pull on the handle to verify proper operation TERRAIN DOMINATION gt POLARIS CFI RECOIL ASSEMBLY Rope Removal and Installation Engine and Cooling Systems TAB ENGAGES INSIDE PULLEY SCREWS RECOIL SPRING FRICTION SPRING SCREWS S PLATE RATCHET GUIDE TAB ENGAGES INSIDE HOUSING Cover Hub Screws 9 Ft Lbs 12Nm Friction Plate Screw 1204173 Recoil Assembly 9 Ft Lbs 12 Nm 1204331 Recoil Assembly 14 Ft Lbs 12 Nm CAUTION Recoil spring under high tension Wear eye protection 1 Remove recoil housing from the engine Un tie knot in the recoil rope and allow the reel to slowly unwind 2 Remove the screw washer friction plate ratchet guide friction spring ratchet and return spring from the reel 3 Liftthe reel straight out of the housing making sure the spring is no longer connected to the backside of the reel NOTE If the recoil spring tension is removed the spring should stay inside the
40. eller nut impeller and washers from the cross shaft 5 Carefully pry the mechanical seal and seal out of the crankcase 6 Water pump assembly is the reverse of disassembly Always use new seals and gaskets during assembly 7 To remove the oil pump cover remove the two fasteners then pull the pump cover out of the crankcase bore Discard the gasket 8 Thecross shaft can be extracted from the water pump side of the crankcase 9 Assembly is the reverse of disassembly Always use new o rings seals and gaskets during assembly 10 Install a new seal onto the shaft from the water pump side 11 To install a new water pump seal use the seal installation tool PN 2872010 Verify the seal lips are facing the cross shaft gear TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual lt gt POLRHIS 2010 Polaris Sales Inc 5 39 Engine and Cooling Systems 600 700 CFI Cylinder Head Cylinders Pistons X n HEAD COVER Des THERMOSTAT O RINGS GASKET CYLINDER HEAD PISTON RINGS S O PISTON BEARING PISTON PIN w C CLIP ey 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 5 40 TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual 2
41. eners 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 7 Reinstall the crankshaft back into the lower crankcase using two new crankcase seals 8 Apply a thin bead of Three Bond 1217H 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 TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual lt gt POLRHIS 2010 Polaris Sales Inc 5 49 Engine and Cooling Systems 600 700 800 CFI Water Oil Pump Assembly SEAL 70 MECHANICAL SEAL WASTER PUMP COVER GASKET IMPELLER B OIL PUMP er 0 Ra CROSS SHAFT B ge 0 2 Se TEE FITTING ey T A 7 Ft Lbs 9 5 Nm B 10 Ft Lbs 13 Nm C 9 Ft Lbs 12 Nm TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual gt POLARIS 2010 Polaris Sales Inc 5 50 Engine and Cooling Systems Disassembly Assembly Process IMPORTANT Use the mechanical seal installation tool to ins
42. ft at point A You will use the tool from the alignment kit PN 2870569 HIGH 002 05mm 005 13mm If the crank rod pin location is 180 from the dial indicator opposite of above it will be necessary to spread the crankshaft at the A position as shown in illustration 3 When rebuilding and straightening a crankshaft straightness is of utmost importance Runout must be as close to zero as possible 5 14 HIGH 002 0O5mm A HIGH 005 13mm 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc TERRAIN DOMINAT gt POLARIS Oil Pump Bushing End Play Fuji Engines When removing the oil pump always retain the original shims installed between the pump and bushing These shims can be re used if the original oil pump and bushing are installed into the engine If any one of these parts are replaced with new components the oil pump and pump bore must be measured to determine if shims will be add ed or subtracted from the assembly 1 Install oil pump drive gear into crankcase Install bushing into bore Verify the bushing is fully seated 2 Measure from the oil pump mounting surface to the top of the bushing Record measurement as MEASUREMENT A MEASUREMENT A 3 Measure the distance between the oil pump mounting flange surface to end of seal flange as shown below Record measurement as MEASUREMENT B NOTE On 550 engines make sure the g
43. he oil pump Insert a screw or similar plug into the hose end and secure with clamp 27 Remove the throttle body or carburetor rack 28 Remove the oil cable lock nut from the threads on the cable housing 29 Remove the throttle cable from the oil pump bracket 30 Remove the oil cable from the oil pump lever by holding the pump open and rotating the cable and keeper to the slot in the pump arm 22 On CFI models remove the Schrader valve cover located under the steering hoop and depressurize the fuel rail See Fuel Rail Bleeding Pressure Testing on page 4 37 31 Remove the cable from the oil pump bracket 32 Remove the engine from the chassis 33 Inspect the motor mounts and replace if needed 23 Using the fuel line disconnection tool PN PS 47152 20 separate the fuel filter and the fuel return line 24 Secure the loose fuel lines out of the way for engine removal NOTE An assistant will be needed for the following steps TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual lt gt POLRHIS 2010 Polaris Sales Inc 5 55 Engine and Cooling Systems Engine Installation Typical 1 Make sure that you have the engine assembled in the state that it was when it was removed This includes all the coolant hoses oil lines and electrical wires 2 Fill oil lines with 2 stroke engine oil when assembling 3 Clean the oil residue and debris out of the engine compartment 4 To a
44. he piston and rod abruptly against the 70 In Lbs 8 Nm crankcase B 9 Ft Lbs 12 Nm Apply Loctite 242 10 Remove the cylinder base gaskets Use a gasket C 25 Ft Lbs 34 Nm Apply Loctite 242 scraper to clean the gasket residue from the D 18 Ft Lbs 24 Nm Apply Pipe Sealant crankcase and cylinder bases E 168 In Lbs 19 Nm Clean and Dry 11 Inspect the cylinder walls Nicasil cylinders can only F 37 Ft Lbs 50 Nm be lightly honed Damage that cannot be removed with a light hone requires cylinder replacement or re lining 12 The assembly process is the reverse of disassembly 1 Remove the coolant from the engine using a siphon 13 Always use new gaskets and o rings during wet dry vac or drain pan assembly Liberally coat the inside of each cylinder 2 Remove the air box exhaust pipe and resonator from and the outside of each piston with Polaris two stroke the engine compartment engine oil 3 Remove the high tension wires and spark plugs from 14 When installing a piston into a cylinder verify each Disassembly Assembly Process the cylinder head piston ring opening is located at each piston ring 4 Remove the thermostat housing outlet cooling hose locating pin Squeeze the top ring then carefully slide from the housing the cylinder over the compressed ring Do the same 5 Loosen all then remove all head cover fasteners with the bottom ring Clean the fastener threads to remove any thr
45. he vertical cover fasteners to specification e T Cover Base Fastener Torque 12 Ft Lbs 16 Nm 10 Install anew gasket on the cylinder then install the EV assembly The guillotine shaft will only fit into the cylinder the correct way If the shaft will not slide in verify it is installed correctly 11 Torque the horizontal cover screws to specification 2 Remove the two horizontal cover fasteners securing Exh Valve Spri the valve assembly to the cylinder xhaust Valve Springs 3 Remove exhaust valve assembly from cylinder 4 Remove the gasket and discard Remove the two vertical cover screws to access the spring and A CAUTION bellows 5 Secure the guillotine then apply heat to remove the Do not substitute different color springs on solenoid bellows cap nut Discard the nut controlled EV engines 6 Separate the cap nut bellows and bellows washer from the guillotine FREE LENGTH 7 Remove the guillotine from the base SPRING COLOR INCHES 8 Thoroughly clean the guillotine using a parts solvent stiff brush emery cloth or similar material Do not 7041704 01 Blue 1 752 scratch the blade surface during cleaning 7041704 02 Orange 1 729 9 Inspect the bellows for tears and wear Replace as required 7041704 03 Pink 1 734 10 Inspect each spring s free length Replace if springs 7041704 04 Purple 1 726 are rusted or excessively worn 11 Thoroughly clean each
46. ing Systems 550 Magneto Assembly SPARK PLUG CAPS CLA CDI MODULE S Disassembly Assembly Process 4 Thoroughly clean the crankshaft nose and flywheel nut threads Inspect the flywheel key for damage 1 Remove the blower recoil housing from the engine Replace if damage is found 2 To remove the flywheel nut and washer secure the 5 Scribe a line in the magneto plate and crankcase to flywheel using the flywheel holding wrench PN ensure alignment when re assembled 8700229 6 Assembly is the reverse of disassembly wrench around the fan blades as blade damage may occur Flywheel and Flywheel Nut 58 72 1 105 crankshaft tapers 3 Remove the flywheel from the crankshaft using the 78 5 98 be clean and heavy duty flywheel puller PN 2871043 A dry Magneto 5 6 5 ft lbs NOTE Do not thread the flywheel puller bolts into Magneto Plate 7 9 the magneto stator located behind the flywheel 5 28 9922854 2007 2011 IQ Service Manual e PLRHBRIS 2010 Polaris Sales Inc 550 Crankcase Assembly Engine and Cooling Systems CRANKCASE SEAL CRANKCASE SEAL Disassembly Assembly Process 1 TERRAIN DOMINATION Remove the blower housing assembly oil pump flywheel and magneto and cylinders from the crankcase assembly Discard all gaskets and o rings Remove engine mount plate fasteners from the lower crankc
47. linder Pistons A BLEED SCREW Ts B D THERMOSTAT COVER THERMOSTAT bos i SPARK PLUGS HEAD COVER s e TEMP SENSOR CYLINDER us D e O RINGS PN THROTTLE BODY HOSE SEE PLUG BYPASS MATRIX ey 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 5 42 TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc gt POLARIS Engine and Cooling Systems 800 CFI Cylinder Head Cylinder Pistons Compatibility Piston Matrix Engine Model Piston PN Piston ID All 800s 2204154 3265 00 800 dual ring pistons feature two different rings thickness es The upper ring is 1 8mm thick while the lower ring is 1 5mm thick 800 CFI engines used in all non RMK or RMK vehicles featuring a front bulkhead cooler are equipped with a by pass nozzle that directs coolant to the front bulkhead cooler 800 CFI engines used in RMK vehicles that do not feature a front bulkhead cooler are equipped with a plug Plug Bypass Matrix Cylinder Head Plug Cylinder Head Engine Model Bypass Nozzle 53489 8044 53683 8044 53685 8044 54001 8044 53471 8044 53684 8044 X 54002
48. om the bulkhead TERRAIN DOMINATION gt POLARIS 9922854 2007 2011 IQ Service Manual 5 23 2010 Polaris Sales Inc Engine and Cooling Systems 2008 2009 IQ CFI 2010 2011 IQ CFI Touring 600 IQ Widetrak Engine Mounting 2 TORQUE STOP ve m os 478 B A lt at a gt RH ENGINE STRAP WASHER ENGINE MOUNT aid SCREW 3 8x16x2 25 NC C UPPER ENGINE MOUNT CLINCH CES i E Sag BOTTOM ENGINE MOUNT ey T A 28 Ft Lbs 38 Nm B 15 Ft Lbs 20 Nm C 30 Ft Lbs 41 Nm LH ENGINE STRAP NOTE Use an engine mount socket PN 2871989 to remove the engine mounts from the bulkhead TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual C POLARIS 2010 Polaris Sales Inc 5 24 Engine and Cooling Systems ENGINE COMPONENT ASSEMBLIES 550 Blower Housing Assembly RATCHET FRICTION SPRING RATCHET SPRIN pees RECOIL PULLEY RECOIL FAN HOUSING Disassembly Assembly Process remove the rear blower housing 1 Clamp recoil rope with a pliers at the engine Remove Fastener Torque Note recoil handle from rope pull the rope through the console then tie a knot just above the pliers Remove Recoil Hub 9 ft lbs 12 Nm the pliers Friction Plate 2 Remove the screws that mount the upper and lower Recoil Pulley 5 405 7 Nm blower housings to the engine 3 Remov
49. ounting TORQUE STOP RH ENGINE STRAP ENGINE MOUNT ENGINE MOUNT BRACKET CLINCH PLATE ISOLATOR A 28 Ft Lbs 38 Nm B 15 Ft Lbs 20 Nm C 30 Ft Lbs 41 Nm NOTE Use an engine mount socket PN 2871989 to remove the engine mounts from the bulkhead TERRAIN DOMINATION POLARIS 9922854 2007 2011 IQ Service Manual 5 21 2010 Polaris Sales Inc Engine and Cooling Systems 2008 2009 IQ Carbureted Engine Mounting TORQUE STOP B S gt DD A a ENGINE MOUNT 9 ar ENGINE MOUNT BRACKET LH ENGINE STRAP Q a CLINCH PLATE ey T A 28 Ft Lbs 38 Nm B 15 Ft Lbs 20 Nm C 45 Ft Lbs 61 Nm NOTE Use an engine mount socket PN 2871989 to remove the engine mounts from the bulkhead TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual gt POLARIS 2010 Polaris Sales Inc 5 22 Engine and Cooling Systems 2007 IQ 700 2010 2011 IQ CFI Engine Mounting TORQUE STOP RH ENGINE STRAP ENGINE MOUNT WASHER 9 ENGINE MOUNT BRACKET LH ENGINE STRAP SCREW 7 16 14 2 25 SC 4 Su UPPER ENGINE MOUNT a 4 CLINCH PLATES D a BOTTOM ENGINE MOUNT A SPACER ey T A 28 Ft Lbs 38 Nm B 15 Ft Lbs 20 Nm C 30 Ft Lbs 41 Nm D 40 Ft Lbs 54 Nm NOTE Use an engine mount socket PN 2871989 to remove the engine mounts fr
50. p fasteners and torque to 24 specification Rear Torque Stop Fasteners 28 ft lb 37 9 N m TERRAIN DOMINATION lt gt POLARIS 9922854 2007 2011 IQ Service Manual 25 26 27 28 Install the air box onto the carburetor rack Make sure to line up the air box tabs with the air box plate Install the drive clutch See Drive Clutch Installation on page 7 23 Install the driven clutch See Driven Clutch Installation on page 7 23 Install the drive belt On CFI models connect he fuel filter and fuel return line by pushing them together until you hear a audible click 5 57 2010 Polaris Sales Inc Engine and Cooling Systems 29 Secure the fuel return line clamp onto the side of 34 Connect the regulator rectifier connections the airbox 7 lt w 7 CAUTION ALWAYS SECURE THE P CLAMP AROUND THE HOSE WHERE THE HOSE MEETS THE METAL CONNECTOR ALWAYS INSPECT FUEL SUPPLY AND RETURN HOSE ROUTINGS AND VERIFY THEY DO NOT MAKE CONTACT WITH EACH OTHER OR OTHER COMPONENTS 30 Place the fuel filter back into the airbox mounted holder 31 Connect the ECU connection into the ECU 32 Connect the EV solenoid connection to the EV solenoid 33 Connect the coil connections to the coils back onto the EV bases and install the panduit strap around the spark plug wires as shown NOTE The WHITE connector goes to the MAG coil upper The B
51. rvice Manual 2010 Polaris Sales Inc 7 Install head gasket with EX on the exhaust side of the engine and on the intake side of the engine 8 Verify vibration dampener is installed between cylinders before installing blower housing covers Fastener Torque Note 25 29 ft lbs Cylinder Base Nut 34 40 Nm Cylinder Head 17 20 1 105 Screws 23 28 Nm Intake Boots 5 ft lbs 7 Nm TERRAIN DOMINATION POLARIS Engine and Cooling Systems 550 Oil Pump Assembly CHECK VALVE ARROW TO OIL TANK AS 2 FITTING AIR BLEED HOSE WASHER J BUSHING SHIM WASHERS AS REQUIRED QTY Disassembly Assembly Process Verify return spring works and applies tension to the lever 1 Remove the two pump mounting screws Pull pump 7 Follow the oil pump bleed procedure outlined in the out of crankcase bore Discard o ring Maintenance chapter 2 Extract shim s behind pump body Count the number of shims and retain Fastener Torque Note 3 Extract bushing and inspect Replace if abnormal 4 Remove drive gear using a needle nose pliers 5 5 8 3Nm _ serviceable 5 Lubricate all parts with Polaris Two Stroke engine oil during re assembly 6 Install the exact amount of shim s that were removed TERRAIN DOMINATION gt POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 5 27 Engine and Cool
52. rvice Manual 2010 Polaris Sales Inc gt POLARIS Engine and Cooling Systems Disassembly Assembly Process 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 Usingthe 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 9922854 2007 2011 IQ Service Manual 5 45 lt gt POLRHIS 2010 Polaris Sales Inc Engine and Cooling Systems 600 700 CFI Crankcase Crankshaft Assembly Q CYLINDER STUDS GEAR CLAMPS 00 92 e oet A pA mn lU
53. sing at the rope guide hole 16 Wind the recoil pulley counterclockwise until the spring begins to bind Unwind the pulley clockwise two revolutions 17 Pull on the rope to disengage it from the notch in the pulley Un tie the knot in the rope and allow it to retract into the housing 18 Pull on the handle to verify proper operation 5 17 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Engine and Cooling Systems EXHAUST VALVE MAINTENANCE Exhaust Assembly View VERTICAL SCREW s HORIZONTAL SCREWS BELLOWS CAP NUT 9 BELLOWS WASHER EV BASE w FITTING GASKET GUILLOTINE Exhaust Valve Disassembly Ay CAUTION EV spring under tension Use care when removing housing from assembly base Remove the vent hose from the base Exhaust Valve Assembly 1 Clean the threads of the guillotine with Loctite Primer N 2 Insert the guillotine into the base housing 3 Apply Loctite 2760 to the first 3 threads on the guillotine 4 Place the bellows washer bellows and a new cap nut onto the guillotine Ensure the bellows is seated correctly between the washer and cap nut 5 Torque the cap nut to specification ey T Guillotine Cap Nut Torque 16 Ft Lbs 22 Nm 6 Lubricate the guillotine blade and shaft with engine oil 7 Actuate the guillotine to ensure full and free motion 8 Install the spring and cover 9 Torque t
54. ssure a smooth transition of the engine into the engine compartment secure all loose hoses that are inside the engine compartment NOTE You may need a helper with the installation of the throttle and oil cables 5 Place the engine on the shock tower brace 6 With the throttle body or carburetor rack separated from the intake adapters route the throttle cable behind the fuel rail or under the carburetor rack and insert the throttle cable into the throttle pulley located in the center of the throttle bodies 7 Insert the throttle body into the adapters and tighten the clamps in the orientation as shown below 8 Adjustthe throttle cable adjuster nut so that you have the correct throttle free play 9 Place the oil cable into the oil pump arm The oil pump arm has a slot in the back to slide the cable through for installation The plastic end of the throttle cable is inserted so that the large flat is facing the engine and the small end is facing the out side 5 56 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 10 Using a 10mm open end wrench tighten the lock nut while holding the other nut with a 10mm open end wrench Make sure that the oil cable angle is tilted slightly toward the engine 11 Threadon the adjuster nut and adjustthe oil pump and adjust the oil pump 12 Reconnect the oil supply hose Open the oil pump bleed screw to purge air from hose 13 Carefully place the engine into the
55. stems Piston Inspection Check piston for scoring or cracks in piston crown or pin area Excessive carbon buildup below the ring lands is an indication of piston ring or cylinder wear Measure piston outside diameter at a 90 angle to the direction of the piston pin and at the specified measuring point MEASURING POINT 2202258 2203319 2203312 Pistons 8mm 2203512 2203707 2203606 2203899 2204122 Pistons 22mm 2204154 800 Pistons 24 5mm Fuji Pistons 12 7mm Subtract this measurement from the minimum cylinder measurement 90 to the pin If clearance exceeds the service limit the cylinder should be re bored replaced if Nicasil lined and new pistons and rings installed TERRAIN DOMINATION POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Piston Ring Installed Gap Piston Ring Piston Ring S 1 2 1 3cm Feeler Gauge 7 i Position the ring 1 2 1 3 cm from the top of the cylinder using the piston to push it squarely into place Measure installed gap with a feeler gauge at both the top and bottom of the cylinder NOTE A difference in end gap indicates cylinder taper The cylinder should be measured for excessive taper and out of round Replace rings if the installed end gap exceeds the service limit Always check piston ring installed gap after re boring a cylinder or when installing new rings m Straigh
56. t 136 Switchback 136 4217 6044 OO6H 2011 600 IQ LXT 4216 6044 OO6H 600 Widetrak IQ 54219 6044 6 600 RMK 144 155 54218 6044 6 TERRAIN DOMINATION gt POLARIS 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc 5 3 Engine and Cooling Systems Engine Specifications 2007 2011 600 700 Engines PISTON TO ENGINE MODEL INSTALLED HEAD HEAD SQUISH CYLINDER PISTON RING END TRIGGER TO VOLUME GAP FLYWHEEL GAP NUMBER cc INCHES MM CLEARANCE INCHES MM INCHES MM S3273 6044 PU6F S3274 6044 PU6F 53466 6044 27 6 28 9 21 um e 4 8 S3467 6044 PU6F 53675 6044 6 004 006 105 159 _ S3206 6044 PU6H Service Parts ace o8 0033 005 085 137 26 65 28 15 53468 6044 6 0034 007 53469 6044 6 086 178 3677 6044 PN6H Service Parts 53908 6044 6 0033 005 S4217 6044 OO6H 045 058 085 137 1 143 1 482 S4176 6044 OP6H S4177 6044 OP6H 25 65 27 15 54218 6044 6 0177 026 I 5 0033 005 450 650 4203 6044 OP6M _ 085 137 54219 6044 6 36 1 34 53747 6044 6 014 020 S3996 6044 OP6H 25 65 27 15 0034 007 356 508 54216 6044 6 086 178 S3305 7044 PF7J 10044 00594 017 026 83471 7044 7 112 151 44 650 S3680 7044 PN7J penes S4175 7044 OP7J 046 059 29
57. t Edge Keystone Piston Ring Cutaway Piston rings are installed with marking or beveled side up 5 9 Engine and Cooling Systems Reed Valve Inspection 1 Loosen hose clamps 2 Remove the carburetor or the throttle body from the intake boots 3 Remove the intake boot fasteners and hose holders if applicable 4 Remove the intake assembly Separate the intake boot s from the reed cage 6 Separate the reed stuffer s from the reed cage and inspect the reeds before they are removed from the reed cage e NOTE Measure the air gap between the fiber reed and the reed block The air gap should not exceed 015 38mm If clearance is excessive DO NOT attempt to reverse the reeds to reduce the air gap Always replace them if damaged or worn Check each fiber reed for white stress marks or missing material The air gap should not exceed 015 30mm 7 If damaged remove and replace the reeds on the reed cage 5 10 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Bearing Fit Any time crankshaft bearing failure occurs and the case is reused check the bearing fit into the case halves using the following procedure With case halves cleaned reinstall the main bearings with a piece of Plastigage between the bearing race and crankcase Install and torque the crankcase fasteners to specifica tion Take the crankcase apart and then measure the Plastigage
58. tall the water pump seal PN 2872010 1 Remove the coolant from the engine using a siphon wet dry vac or a drain pan 2 Remove the airbox exhaust pipe and resonator Remove the hose connected to the water pump cover 3 access the impeller and mechanical seal remove the water pump cover Discard the water pump cover gasket 4 Remove the impeller nut impeller and washers from the cross shaft 5 Carefully pry the mechanical seal and seal out of the crankcase 6 Water pump assembly is the reverse of disassembly Always use new seals and gaskets during assembly 7 To remove the oil pump remove the two fasteners then pull the pump cover out of the crankcase bore Discard the gasket 8 To remove the oil pump cover remove the two fasteners then pull the pump cover out of the crankcase bore Discard the gasket 9 Thecross shaft can be extracted from the water pump side of the crankcase 10 Assembly is the reverse of disassembly Always use new o rings seals and gaskets during assembly 11 Install a new seal onto the shaft from the water pump side 12 To install a new water pump seal use the seal installation tool PN 2872010 Verify the seal lips are facing the cross shaft gear TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual lt gt POLRHIS 2010 Polaris Sales Inc 5 51 Engine and Cooling Systems 600 700 800 Oil Hose Routing TEE FITTING
59. the pulley is removed 4 Inspect all components for signs of abnormal wear and tear Replace components as required If replacing the rope tie a small square knot at one end Push the knot firmly into the pocket on the pulley 5 f the pulley recoil spring was removed during disassembly install the spring by spiraling the spring counterclockwise toward the center of the housing 6 Lubricate the center shaft and spring with Premium grease 7 Wind the rope counterclockwise around the pulley as 5 16 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc amp 2 ROPE GUIDE HOLE 2 RATCHET SPRING ay RECOIL SPRING TAB ENGAGES INSIDE HOUSING viewed from the ratchet side of the pulley A CAUTION 8 Pass the end of the rope through the hole in the housing If the rope guide was removed from the housing reinstall it before attaching the rope handle 9 Slide the pulley down the center shaft and into the housing making sure the recoil spring re engages the pulley tab 10 Install the ratchet spring and ratchet into the pulley face The ratchet spring leg fits in the notch on the ratchet and holds the ratchet in retracted 11 Install friction spring with one leg inserted in the bottom hole on the ratchet 12 Install nut and torque to 5 ft lbs 7 Nm 13 Pull rope out to its full extension and align pulley notch with rope hole in housing 14 Using a needle nose pliers or hook
60. then pulling the airbox assembly out of the engine compartment On CFI models disconnect the main harness at the ECU This is the smaller of the two plugs located on the ECU Remove it by pressing up on the underside of the plug and pulling straight off 5 53 Engine and Cooling Systems 13 Disconnect the EV solenoid from the ECU harness secure the loose hoses out of the way for engine 7 removal 19 Remove the four right hand chassis brace fasteners and remove the brace from the chassis 14 Disconnect the EV vent lines from the EV base and secure the vent lines out of the way 20 Remove the engine isolator and rear torque stop located on the left hand side of the engine where equipped 15 Remove the drive belt driven and drive clutches See Chapter 6 16 Remove the recoil rope from the handle and route rope through the guide on the chassis brace and secure the recoil rope by tying a knot so that it does not go into the recoil housing 17 Drain the coolant from the engine into a suitable container 18 Remove all coolant hoses from the coolant bottle and 5 54 TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual C POLARIS 2010 Polaris Sales Inc Engine and Cooling Systems 21 Remove the four engine mounting fasteners located 25 Lift engine out of chassis and carefully place engine on the engine straps on shock tower brace 26 Remove the oil supply hose from t
61. thin bead of Three Bond 1217H 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 TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual lt gt POLRHIS 2010 Polaris Sales Inc 5 47 Engine and Cooling Systems 800 CFI Crankcase Crankshaft GEAR CLAMPS Q Deus ADAPTER PLATE ALIGNMENT DOWELS SEAL GUARD REED BLOCKS STATOR WIRE RETAINER Qa Q 2 5 OIL INJECTION CHECK VALVE QTY 5 FLYWHEEL KEY MAG BEARING MAG SEAL STATOR WIRE RETAINER 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 TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual C POLARIS 2010 Polaris Sales Inc 5 48 Engine and Cooling Systems Disassembly Assembly Process 800 CFI Crankcase Crankshaft 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 fast
62. ure and hot Escap ing steam and or coolant may cause severe burns to ex posed skin 1 Remove the housing cover by removing the cover bolts 2 Check the gasket condition and replace if damaged 3 Replace the thermostat Make sure that the spring side is facing downward or toward the engine 4 Replace cover Torque the cover fasteners to specification Cover Fasteners 9 Ft Lbs 12 Nm 5 59 9922854 2007 2011 IQ Service Manual 2010 Polaris Sales Inc Engine and Cooling Systems 5 Verify the bleed screw and washer are installed Thermostat Orientation The thermostat must be installed in the cylinder head has shown in the illustrations Center Thermostat Location BRIDGE ALIGNED WITH HOLES y gt gt j LIBERTY gt 59 WY Wi 800 CFI Thermostats There are two different thermostats used depending on if the engine is installed in a vehicle with or without a front tunnel bypass cooler Cooling System Type Thermostat PN Bleed Hole ID Bypass Cooler 7052433 2mm No FRT Cooler 7052452 3 5mm The larger bleed hole thermostat is designed for cooling systems that do not feature a bypass circuit in the cooling system Both thermostats are full open at 120 F 49 C TERRAIN DOMINATION 9922854 2007 2011 IQ Service Manual gt POLARIS 2010 Polaris Sales Inc 5 60 Engine
63. y as possible by finding the center of the point where there is no piston movement note the Zero the dial indicator at this point 6 Continue to rotate the crankshaft in the normal direction of rotation until the dial indicator reads 100 2 54mm after top dead center ATDC 7 Bend the pointer or move the degree wheel until the pointer aligns with a 180 mark on the degree wheel 8 With the pointer aligned make sure the degree wheel and pointer are secured and will not move out of position Re check accuracy of this location a few times The pointer should align with the 180 mark when the dial indicator reads 100 2 54mm NOTE Do not move the crankshaft degree wheel or pointer after the initial setting on the MAG end cylinder simply read the wheel and dial indicator 9 Remove the dial indicator and install in PTO cylinder Repeat finding TDC process Note the degree wheel indication when the dial indicator reads 100 ATDC It should be 180 2 from the MAG cylinder mark 100 ATDC TERRAIN DOMINATION POLARIS Engine and Cooling Systems Cylinder Honing The cylinder bore must be de glazed whenever new pis ton rings are installed A light honing with fine stones re moves only a very small amount of material A proper crosshatch pattern is important to provide a surface that will hold oil and allow the rings to seat properly If the crosshatch is too steep oil retention will

Engines and Cooling Systems - Les Entreprises Marc Latulippe

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