1999 Polaris Service Manual
Contents
1. Straight Edge Piston Ring Cutaway Keystone Piston Ring Polaris Industries Inc 3 81 10 98 ENGINES General Inspection Procedures Oil Pump Operation and Troubleshooting Any time the engine is disassembled or repaired it is important that the oil supply from the pump to the engine be checked NOTE Banjo type or pressed in valves should open with 2 to 7 Ibs of pressure Perform this test with 40 1 premix in fuel tank 1 With engine in chassis oil reservoir full and pump bled remove two oil feed line banjo bolts A from their location on the manifold or carburetors NOTE Install new sealing washers upon installation on either side of the banjo check valve Apply Pressure Here To Test Pressed 2 Loosely thread only the banjo bolts back into the manifold or carburetors 3 Place oil feed lines with their check valves away from the clutch area Start the engine and let it idle at normal idle RPM 4 Lift oil pump control lever up to its maximum flow position 5 Drops of oil should be visible from the banjo check valves after the engine is idled one to two minutes with a drop occurring approximately every few seconds 6 If oil does not flow from one of the check valves remove oil line from check valve and again idle engine If oil then flows the check valve is defective and must be replaced 7 If oil does not flow with check valves removed from their feed line2. Polaris Industries Inc ENGINES Three Cylinder Monoblock Assembly Cont 7 Before installing cylinder refer to honing procedure on pages 3 73 3 74 of this section Inspect piston to cylinder clearance and piston ring installed gap as shown on page 8 81 Install rings on pistons Depress rings in alignment with locating pins on piston using either a ring Compressor or your fingers Carefully install the cylinder Install pistons in the following order Mag Center e PTO 8 Torque base bolts starting in the middle alternate intake to exhaust side moving toward PTO end and mag end Refer to torque patterns in beginning of this chapter 9 Install new head gasket Be sure cylinder and cylinder head sealing surfaces are clean NOTE EX stamping should be readable and facing ex haust side 10 Install heads in the correct position and location as marked during disassembly Torque head bolts to specification found in the beginning of this chapter Polaris Industries Inc 3 35 10 98 ENGINES Three Cylinder Monoblock Assembly Cont 11 Replace outer O ring on cover 12 Apply Loctite 515 to cover as shown 13 Position shim and O Ring as shown ous Apply Sealant LEA To Top Of Shim O Ring OD 14 Install head cover 15 Install and torgue head cover mounting bolts to specification Head Cover Mounting Bolt Torgue 17 20 Ft lbs 2 4 2 8 kgm
3. 6 Reinstall friction plate with one end of friction spring in hole on end of ratchet pawl 7 Reinstall flange nut and torque to 5 ft Ibs 69 kg m 8 Pull recoil rope to full extension and align notch on outside edge of reel with housing rope guide hole 9 Using a needle nose pliers or hooked wire pull a loop of rope through the notch into center of housing 10 Holding side of rope loop attached to reel wind reel counterclockwise until coil bind is felt Then unwind reel between one and two turns 11 Pull loop to outside of housing by pulling on rope handle 12 Allow rope to fully retract and check for normal recoil and ratchet operation Polaris Industries Inc 3 93 10 98 ENGINES Troubleshooting PROBLEM PROBABLE CAUSE Will not start Check ignition switch for run position moisture contamination hard starting Check auxiliary shut off switch operation Check fuel supply Check wiring from engine to coil s or spark plug s Check spark plug s Disconnect engine connector to eliminate any shorts that might be in the system lf starter won t work electric models check wires from starter solenoid and battery or check battery and battery cables Open or broken reed valves Low compres Crankcase plug is out sion Head gasket faulty Poor ring sealing piston damage No spark Spark plug fouled Secondary coil faulty or wires disconnected poor ground on secondary coil mount Primary coil s
4. 16 Install stator in the previously marked position and tighten screws securely 17 Install and torque flywheel nut to specification found in beginning of this chapter Flywheel Holder Wrench PN 8700229 18 Install water pump and belt Apply proper tension to belt and tighten pump mounting bolts Water Pump Belt Tension 1 8 3 16 3 4mm 10 98 3 36 Polaris Industries Inc ENGINES Three Cylinder Monoblock Assembly Cont 19 Install oil pump and connect feed lines H crankcase oil pump or drive components were replaced refer to oil pump drive gear end play adjustment in General Inspection Procedures 20 Install recoil housing 21 Install secondary coils and secure carburetors to rubber mounts Polaris Industries Inc 3 37 10 98 ENGINES 440 500 Domestic Case Reed Twin NOTE Inspect all parts for wear or damage during disassembly Replace all seals O rings and gaskets during disassembly Refer to pages 3 73 3 84 for general inspection proce dures Disassembly 1 Remove carburetor mount adaptors reed cages stuffers and oil pump Note position of stator wire guide Reed Pedal Clearance 015 38 mm max Exaggerated for illustration Measure air gap between fiber reed and reed block as shown The air gap should not exceed 015 4 mm lf clearance is excessive DO NOT attempt to reverse the reeds to reduce the air gap Always replace them if damaged Check
5. Polaris Industries Inc 3 31 10 98 12 Remove cylinder heads Mark PTO Center and Three Cylinder Monoblock Disassembly Cont ENGINES Mag head to ensure correct reassembly i D gt Q O D fasi D LE i D 3 gt O f Cylinder Heads Mark For Reassembly 14 Refer to cylinder inspection procedure on page 3 86 13 Remove cylinder and base gasket to inspect cylinder cee Use care to ensure pistons are not damaged as cylinder is removed 15 Support pistons with piston support block and remove C clips Polaris Industries Inc 3 32 10 98 Disassembly Cont 16 Remove piston pins using piston pin puller and adaptor as shown Refer to General Inspection Procedures in this section Piston Pin Puller PN 2870386 Adapter PN 5130971 17 Remove all crankcase bolts 18 Separate crankcase halves and remove crankshaft 19 Follow procedure in General Inspection Procedures for crankshaft inspection 20 Clean all components in a solvent tank to remove any dust dirt debris and excess sealant Inspect mating surface of upper and lower crankcase for damage Polaris Industries Inc 3 33 ENGINES Three Cylinder Monoblock 10 98 ENGIN
6. GEN Hose autostat 0 Au Z 1 rs to brake cooler g Hose autostat to engine Hose autostat to middle tank fitting NOTE When leak testing cooling system system pressure should not exceed 2 Ibs less than cap pres sure Refer to filling and bleeding procedure on page 3 85 TUNNEL COOLERS 10 98 3 92 Polaris Industries Inc ENGINES Recoil Starter Spring Replacement Disassembly Wear eye protection when servicing recoil Spring can unwind suddenly and unexpectedly if dislodged 1 Remove recoil handle and allow rope to retract and spring to unwind completely 2 Remove retaining nut friction plate and ratchet pawl from reel face 3 Lift reel assembly straight up out of housing NOTE lf spring tension is relieved and the reel is lifted straight out the spring will most likely remain in the housing however be sure to heed caution above Assembly 1 If the spring was removed reinstall it by spiraling counterclockwise toward the center 2 Lubricate center shaft and spring with grease Premium All Season Grease PN 2871423 14 oz 8 Wind rope in a counterclockwise direction around outside of reel as viewed from ratchet side of reel 4 Pass end of rope through rope guide and slide reel down onto shaft and spring NOTE Make sure reel tab engages hook on end of spring 5 Reinstall ratchet pawl onto reel face NOTE Ratchet spring must hold ratchet in retracted position
7. 025mm Crankshaft Main Bearing Inspection 1 Clean crankshaft thoroughly and oil main and connecting rod bearings with Polaris Premium 2 engine oil Carefully check each main bearing on the shaft NOTE 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 bear ings Polaris Industries Inc 3 75 ENGINES General Inspection Procedures 10 98 ENGINES General Inspection Procedures Connecting Rod Big End Bearing Inspection 1 Measure connecting rod big end side clearance with a feeler gauge Clearance should be equal on all rods within 002 Rotate rod on crankshaft and check for rough spots Check radial end play in rod 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 NOTE Specialized equipment and a sound knowledge of crankshaft repair and straightening is required to per form crankshaft work safely and correctly Crankshaft repair should be performed by
8. end at the outer perimeter of the degree wheel 3 Install a dial indicator into the magneto end cylinder spark plug hole front 1 The ignition timing is referenced by the magneto end 4 Rotate the engine to bring the piston to top dead center TDC on the cylinder with the indicator installed 5 Locate TDC as accurately as possible by finding the center of the point where there is no piston movement Zero the dial indicator at this point Continue to rotate the crankshaft in the normal direction of rotation until the dial indicator reads 100 2 54mm after top dead center ATDC IMPORTANT Do not allow the crankshaft to move from this position 10 98 3 78 Dial Indicator Degree Wheel Polaris Industries Inc Crankshaft Indexing Continued 6 Bend the pointer or move the degree wheel until the pointer aligns with the 180 or 120 mark on the degree wheel 7 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 by repeating steps 4 and 5 The pointer should align with the 180 or 120 mark when the dial indicator reads 100 2 54mm ATDC IMPORTANT Do not move the degree wheel or pointer after the initial setting on the mag end cylinder simply read the wheel and dial indicator 8 Remove the dial indicator and install in cylinder 2 or center cylinder Repeat steps 4 and 5 Note the degree
9. 015 38 mm max Exaggerated for illustration 18 Remove cylinder head Note condition and placement of both cylinder head O rings 19 Loosen cylinder base nuts and remove cylinders 10 98 3 54 Polaris Industries Inc ENGINES 600 700 Domestic Case Reed Twin Disassembly Cont 20 Carefully remove C clip holding piston pin in place 21 Remove piston pin using piston pin puller and adaptor Piston Pin Puller PN 2870386 Adaptor PN 5130971 22 Remove water manifold by removing both retainer brackets 23 Remove bottom crankcase bolts and separate crankcase halves Polaris Industries Inc 3 55 10 98 ENGINES 600 700 Domestic Case Reed Twin Disassembly Cont 24 Remove snap rings and crankshaft seals 25 Clean thoroughly to remove all grease oil dirt and old sealant 10 98 3 56 Polaris Industries Inc ENGINES 600 700 Domestic Case Reed Twin Assembly 1 Clean all parts with solvent and dry with compressed air 2 Apply 3 Bond 1215 sealant to upper crankcase half NOTE Use only 3 Bond 1215 sealant Curing time and film thickness are critical for proper bearing clear ance 8 Bond 1215 PN 2871557 120 Gram Tube 3 Set crankshaft in lower crankcase Lubricate seal lips with Premium All Season Grease Make sure seals are positioned properly with lip and spring facing inward toward crankshaft Install snap rings with gap facing up
10. 49 ENGINES 440 500 Domestic Case Reed Twin 10 98 ENGINES 600 700 Domestic Case Reed Twin NOTE Inspect all parts for Wear or damage during disassembly Replace all seals O rings and gaskets during disassembly Refer to pages 3 73 3 84 for general inspection proce dures Disassembly 1 Remove oil pump 2 Remove recoil housing 3 Remove recoil hub Inspect waterpump drive belt for missing cracked or broken drive cogs Replace if worn Measure the belt at 4 different points as shown Re place if width is less than 25 6 35mm Nominal new width is 345 8 75mm Refer to Maintenance chapter for water pump belt installation Replace if width is less than 25 6 35mm 10 98 3 50 Polaris industries Inc ENGINES 600 700 Domestic Case Reed Twin Disassembly Cont 4 Remove drive gears and belt 5 Remove flywheel nut using flywheel holder Flywheel Holder PN 8700229 6 Remove flywheel using flywheel puller Flywheel Puller PN 2871043 7 N ot e t h e g n iti on t i m i n g st ri p on t h e flyw h ee gt Aa se SAANnRen 8 Before removing stator plate mark the plate and crankcase for reference upon assembly Polaris Industries Inc 3 51 10 98 ENGINES 600 700 Domestic Case Reed Twin Disassembly Cont 9 Remove bolts holding water pump housing to crankcase Loosen hose clamp and remove housing 10 Inspect water pump weep hole for signs of leaka
11. Bolt Torque 16 Ft lbs 2 21 kgm 34 Assemble V E S valve Refer to V E S procedures in beginning of this section 35 Install reed valves stuffers and carburetor adaptors Place stator wire guide on Mag side carburetor adaptor bolt 36 Install stator assembly aligning timing marks or marks made upon disassembly Seal stator wires with high temperature silicone sealant Install and tighten stator screws to specification 37 Measure trigger pulse coil gap and compare to specification Stator Screw Torque 60 in Ibs 69 kg m Trigger Pulse Coil Gap Minimum 020 5mm Maximum 040 1 0mm 10 98 3 48 Polaris Industries Inc Assembly Cont 38 39 40 41 42 43 Apply Loctite 262 evenly to the flywheel mounting taper on crankshaft Install woodruff key Install flywheel Apply Loctite 242 to crankshaft threads Install washer and nut Use flywheel holder to hold flywheel and torque nut to specification found in beginning of this chapter Flywheel Holder PN 8700229 Install recoil hub and recoil housing Torque bolts to specification Recoil Hub and Housing Bolt _ Torque 108 in lbs 1 25 kg m Install engine in chassis and align clutches Refer to General Inspection Procedures in this chapter to fill and bleed cooling system and oil pump Polaris Industries Inc 3
12. ENGINES 600 700 Domestic Case Reed Twin Polaris Industries Inc 3 61 10 98 ENGINES 700 800 Case Reed Fuji NOTE Inspect all parts for wear or damage during disassembly Replace all seals O rings and gaskets during disassembly Refer to pages 3 73 3 84 for general inspection proce dures Disassembly 1 Remove carburetors water outlet manifold secondary coils oil pump and reed valve cage assemblies NOTE Mark each components mag center and PTO so they will be in the correct location when reassembling 2 Remove exhaust valve assembly from each cylinder 3 Remove recoil housing water pump belt guard water pump and flywheel nut Flywheel Holder PN 8700229 4 Install flywheel puller and remove flywheel Flywheel Puller PN 2871043 CAUTION Do not thread puller bolts more than 3 8 0 5 mm into flywheel or stator coil damage may occur 10 98 3 62 Polaris Industries Inc Disassembly Cont 5 Mark stator plate at case parting line and remove plate 6 Remove head covers heads and cylinder base nuts 7 Carefully remove cylinders 8 Remove C clip retainers 9 Use piston pin puller to remove piston pins Piston Pin Puller PN 2870386 Polaris Industries Inc 3 63 ENGINES 700 800 Case Reed Fuji _CCUP RETAINERS 10 98 ENGINES 700 800 Case Reed Fuji Disassembly Cont 10 Remove crankcase bo
13. Installation Engine Installation Typical 1 Prepare chassis for engine installation by moving hoses and wiring out of the way 2 If model is equipped with a torque stop loosen locking screw and turn torque stop in to gain clearance when installing engine NOTE Torque stop must be adjusted properly after clutch alignment see chapter 5 clutches 3 Check condition of bonded rubber engine mounts Be sure mounts are tight before installing engine With engine mounting plate or mount straps installed on engine set engine on rubber mounts and loosely install mounting bolts and nuts 4 Install drive belt and clutch if removed and check clutch offset alignment Adjust torque stop where applicable Refer to chapter 5 clutches for torque stop adjustment procedure 5 Tighten engine mounting bolts to specification Engine Mounting Bolt Torque Front 28 Ft Ibs 6 67 kgm Rear 28 Ft Ibs 6 67 kgm Polaris Industries Inc 3 9 10 98 ENGINES Engine Installation Engine Installation Typical Cont 6 Apply a light film of Polaris dielectric grease to all connections Connect all stator connections and temperature switch Dielectric grease PN 2871329 1 4 oz 7 Connect oil supply line to oil pump Bleed oil pump by opening bleed screw until oil flows steadily Tighten bleed screw securely Install throttle cable to oil pump and check adjustment Refer to General Inspection Procedures in this c
14. Lubricate rings and cylinder with Premium 2 Cycle Lubricant and compress rings with fingers aligning end gaps with locating pins Install cylinder with a gentle front to back rocking motion being careful not to damage rings Install cylinder base nuts and tighten to correct specifications found in the beginning of this chapter 10 Install head gasket Note proper position of gasket V notch forward small intake hole on right mag side large hole on left PTO side 11 Install cylinder head and torque cylinder head nuts following torque specs and pattern sequence in the beginning of this chapter 12 Before installing oil pump drive gear refer to end play adjustment in General Inspection Procedures 13 Install oil pump in the sequence shown in photo at right Polaris Industries Inc 3 27 10 98 ENGINES Liquid Twin Cylinder Fuji Assembly Cont 14 Connect oil feed lines to cylinder 15 Align stator as previously marked on stator plate and secure with screws 16 Install flywheel and torque flywheel nut to specification found in beginning of this chapter Flywheel Holding Tool PN 8700229 17 Install water pump and recoil starter cup 18 Adjust tension on water pump belt by loosening mounting bolts applying tension and re tightening bolts Water Pump Belt Deflection 1 8 3 16 3 4 cm 19 Install recoil housing carburetors and oil pump cable Refer to oil pump bleeding
15. Out of Round IT Limit 002 Max Bottom S 10 98 3 80 Polaris Industries Inc Piston Inspection Measurement 1 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 2 Measure piston outside diameter at a point 10 mm 3 8 up from the bottom of the skirt at a 90 angle to the direction of the piston pin Record the measurement for each piston NOTE The piston must be measured at this point to provide accurate piston to cylinder clearance measure ment 3 Subtract this measurement from the minimum cylinder measurement recorded previously If clearance exceeds the service limit the cylinder should be re bored and new pistons and rings installed Piston Ring Installed Gap 1 Position 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 NOTE Always check piston ring installed gap after re boring a cylinder or when installing new rings Refer to specifications in chapter 1 for piston ring installed gap ENGINES General Inspection Procedures
16. at right When A A HIGH 005 13mm rebuilding and straightening a crankshaft straightness is of utmost importance Runout must be as close to zero as possible NOTE Maximum allowable runout is 004 1 mm Polaris Industries Inc 3 77 10 98 ENGINES General Inspection Procedures Crankshaft Indexing Polaris crankshafts are pressed together or indexed so the connecting rod journal center lines are 180 twins or 120 triples apart from each other It is sometimes necessary to check multi cylinder crank shafts to verify that one cylinder has not been forced out of position relative to the other cylinder or cylinders Causes for out of index crankshafts include but are not not limited to e Hydrolock from water or fuel e Impact to drive clutch from foreign object or acci dent e Abrupt piston or other mechanical failure e Engine lock up due to drive belt failure Following is a method of checking Disconnect battery ground cable and all spark plug high tension leads ground high tension leads to engine Dis connect lanyard from engine stop switch before proceed ing with the following steps 1 Securely fasten a degree wheel on the flywheel or PTO end of crankshaft Use a large degree wheel for more accuracy and make sure it is mounted concentrically with the crankshaft center line 2 Sharpen a coat hanger or section of welding rod and anchor it to a convenient spot Point the sharpened
17. bleeding procedure on page 3 85 LH COOLER RH COOLER 10 98 3 86 Polaris Industries Inc ENGINES Cooling System 600 XC SP 700 XC SP Bypass Hose Not Shown WA rn rear wear strip K coolers Wear strip coolers Hose tee to brake cooler Hose tee to pump ie Protective conduit Hose engine out to bottom close off center cooler NOTE When leak testing cooling system system pressure should not exceed 2 lbs less than cap pres sure Refer to filling and bleeding procedure on page 3 85 CENTER COOLER TUNNEL STRIP COOLERS Polaris Industries Inc 3 87 10 98 ENGINES Cooling System 600 RMK 700 RMK 700 SKS Bypass Hose Not Shown Hose tee to bottle V Hose brake coolerto KR zA gt S i a rear extrusion SH ZA a Hose tee to brake cooler ose bulkhead to rear extrusion 4 Protective conduit Hose engine out to bottom close off Hose tee to pump in ENGINE NOTE When leak testing cooling system system pressure should not exceed 2 Ibs less than cap pres sure Refer to filling and bleeding procedure on page 3 85 COOLANT BOTTLE TUNNEL COOLERS 10 98 3 88 Polaris Industries Inc ENGINES Cooling System 440 XCR Hose rear wear strip coolers Hose engine out to brake cooler Hose tee to bottle Hose brake cooler to wear strip Wear strip coolers Hose tee to center cooler Hose clo
18. head bolts to specification found in the beginning of this chapter NOTE Make sure threaded head nuts are in the proper position for shroud mounting See x in photo at right Polaris Industries Inc 3 19 10 98 ENGINES Fan Cooled Twin Cylinder Engine Assembly Cont 12 Install inner fan shroud Do not tighten bolts until outer shroud is bolted in place Outer shroud must determine placement of inner shroud or damage may result 13 Install stator plate aligning ignition timing marks made during disassembly Tighten stator mounting bolts securely 14 Make sure key is on crankshaft and install flywheel aligning keyway 15 Install flywheel nut and torque to specification found in the beginning of this chapter Flywheel Holding Wrench PN 8700229 10 98 3 20 Polaris Industries Inc ENGINES Fan Cooled Twin Cylinder Engine Assembly Cont 16 Install recoil starter hub and recoil housing NOTE Tighten two inner shroud bolts 17 Reassemble cooling shroud 18 Install oil pump If crankcase oil pump or pump drive components were replaced refer to General Inspection Procedures in this chapter to inspect drive gear end play Oil Pump Mounting Screw Torque 48 72 in lbs 55 83 kg m Polaris Industries Inc 3 21 10 98 ENGINES Liquid Twin Cylinder Fuji NOTE Inspect all parts for wear or damage during disassembly Repl
19. in General Inspection Procedures 20 Connect CDI to stator plug connector 10 98 3 28 Polaris Industries Inc ENGINES Three Cylinder Monoblock NOTE Inspect all parts for wear or damage during disassembly Replace all seals O rings and gaskets during disassembly Refer to pages 3 73 3 84 for general inspection proce dures Disassembly 1 Remove carburetors and secondary coils 2 Remove oil pump 3 Remove recoil housing 4 Remove recoil hub Polaris Industries Inc 3 29 10 98 ENGINES Three Cylinder Monoblock Disassembly Cont 5 Remove water pump 6 Remove flywheel retaining nut Position flywheel holder as shown Flywheel Holder PN 8700229 7 Install flywheel puller Remove flywheel Flywheel Puller PN 2871043 _ CAUTION Do not install puller bolts more than 5 16 7 9 mm or stator damage may result 10 98 3 30 Polaris Industries Inc ENGINES Three Cylinder Monoblock Disassembly Cont 8 Mark or note location of stator plate on plate and crankcase 9 Remove stator NOTE Stator bolts may be loosened using an impact driver 10 Remove cylinder head cover 11 Note condition and location of spark plug seat O rings in head cover Also note the quantity and location of shim washers located beneath the O rings
20. piston damage Refer to General Inspection Procedures in this chapter 10 Remove outer piston pin C clips using a scribe through access slot in piston 11 Place support block under piston and remove piston pins using pin puller Piston Pin Puller PN 2870386 Support Block PN 2870390 12 Remove water pump cover from front of engine Polaris Industries Inc 3 41 10 98 ENGINES 440 500 Domestic Case Reed Twin Disassembly Cont 13 Remove recoil housing and drive hub 14 Remove flywheel using heavy duty flywheel puller Use drive clutch puller T handie or a wrench to hold puller Flywheel Puller PN 2871043 T Handle aes PN 5020326 15 Before removing stator plate note where ignition timing marks are located or scribe additional marks for reference upon reassembly 16 Mark or note location of engine mount straps and remove 10 98 3 42 Polaris Industries Inc ENGINES 440 500 Domestic Case Reed Twin Disassembly Cont 17 Remove bolts and separate case halves Keep bolts in order for assembly 18 To prevent damage to snap ring grooves lift crankshaft straight upward and out of lower case 19 If pump shaft removal is necessary remove retaining pin from crankcase using a diagonal cutter or similar tool 20 Using a soft faced hammer tap pum
21. sequence shown at right MAG End PTO End 00 CO ve O amp E Polaris Industries Inc 3 45 10 98 ENGINES 440 500 Domestic Case Reed Twin Assembly Cont 16 17 18 19 20 21 22 28 24 25 __ CAUTION Assemble engine mount straps to crankcase Engine Mount Strap Torque 44 48 ft lbs 6 0 6 6 kg m Lubricate main bearing oil holes with Polaris Premium 2 Cycle or Premium Gold engine oil and rotate crankshaft to distribute oil evenly Install a new C clip in both pistons inside with gap facing down Be sure clip is fully seated in groove Lubricate and install new connecting rod small end bearing in rod Install piston with arrow facing exhaust ring locating pins should be facing intake Warming the piston may help to ease installation of pin Install remaining C clip with gap down Be sure both clips are fully seated on the groove Install new base gasket Be sure gasket surface is clean and free of nicks burrs or scratches Lubricate and install piston rings on piston with mark on end of ring facing upward Place piston support under skirt and lubricate pistons and cylinders thoroughly Align ring end gaps with locating pins and compress rings Install cylinder carefully with a gentle front to rear rocking motion Install cylinder base nuts loosely Do not tighten them at this time Repeat Steps 22 25 for other cylinder Do not t
22. wheel indication when the dial indicator reads 100 ATDC It should be 180 or 120 2 from cylinder 1 Repeat procedure on PTO cylinder 3 where applicable Cylinder 3 should also be 120 2 from cylinder 1 Symptoms of an out of index crankshaft can include e Difficulty calibrating carburetor repetitive plug fouling on one cylinder with no other cause e Unexplained piston failure on one cylinder i e severe detonation broken ring lands piston hol ing e Excessive vibration of engine backfiring etc e Rough idle poor top speed Polaris Industries Inc 3 79 ENGINES General Inspection Procedures 10 98 ENGINES General Inspection Procedures Cylinder Head Inspection 1 Inspect each cylinder head for warping Replace cylinder head if warp exceeds service limit Cylinder Head Warp Service Limit 003 08mm Cylinder Measurement 1 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 of the cylinder and the bottom of the cylinder to determine taper or out of round at the bottom Record all measurements Cylinder Taper Limit 002 Max Middle A Cylinder
23. with new O ring until seated against shaft install oil pump being careful to engage pump shaft in drive shaft Oil Pump Mounting Screw Te rq 60 in Ibs 70 kg m _ Remove bushings seals 10 98 3 44 Polaris Industries Inc ENGINES 440 500 Domestic Case Reed Twin Assembly Cont 7 Install mechanical seal guide special tool on end of pump shaft Washer 10 3x14x1mm 10 ft lbs Mechanical Seal Guide 1 38 kg m Tool 1999 440 500 domestic engines 8 4mm PN 2872010 8 Lubricate seal guide and drive or press a new Mechanical Washer mechanical seal into case until fully seated using s the seal press tool Seal 325x 75x 063 9 Lubricate all crankshaft bearings with Premium 2 Cycle or Premium Gold Engine Lubricant 10 Lightly grease pump shaft drive gear and sealing lip of crankshaft seals 11 Install seals on crankshaft with spring facing inward toward crankshaft 12 Clean and de grease lower crankcase and install crankshaft assembly aligning seals and snap ring with grooves in case 13 Apply a thin coating of 3 Bond 1215 sealant to lower crankcase mating surface 14 Install upper crankcase on lower crankcase 15 Apply Loctite 242 to threads of bolts and install Torque bolts in three steps to specification outlined in beginning of this chapter following the
24. 0 XCR Bleeding Procedure 1 Fill cooling system Leave pressure cap off 2 With engine running at specified idle speed loosen bleed screw on water outlet manifold 3 Continue adding antifreeze mixture to reservoir bottle until system is purged of air Close bleed screw and tighten securely Fill reservoir bottle until it is between the minimum and maximum fill marks 6 Replace pressure cap 7 Start engine and check for leaks 500 600 700 Domestic Twins Bleeding Procedure 700 800 XCR Bleed Screw 1 Fill cooling system Leave pressure cap off 2 With engine running at specified idle speed loosen bleed screw on thermostat housing 3 Continue adding antifreeze mixture to reservoir until system is purged of air 4 Close bleed screw and tighten securely 5 Fill reservoir bottle until coolant level is between the 500 600 700 Domestic Twins minimum and maximum fill marks 6 Replace pressure cap 7 Start engine and test for leaks Polaris Industries Inc 3 85 10 98 ENGINES Cooling System Indy 500 500 RMK Classic Classic Touring Widetrak LX XLT Classic XLT Touring Note Filter is located before the check valve Coolant flows from tank through filter then check valve to water pump Crossover hose Hose filler RH cooler Hose center cooler to pump NOTE When leak testing cooling system system pressure should not exceed 2 Ibs less than cap pres sure Refer to filling and
25. 002mm NOTE Always check piston to cylinder clearance and piston ring installed gap after boring honing is complete Polaris Industries Inc 3 73 10 98 ENGINES General Inspection Procedures Honing Procedure 1 Wash cylinder with solvent Clamp cylinder in a soft jawed vise by the exhaust port studs 2 Place hone in cylinder and tighten stone adjusting knob until stone contacts the cylinder walls DO NOT OVERTIGHTEN Cylinders may be wet or dry honed depending on the hone manufacturer s recommendations Wet honing removes more material faster and leaves a more distinct pattern in the bore 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 3 cm beyond the bore at the end of each stroke Release the hone at regular intervals to inspect bore size and finish Ni Ca Sil Honing Ni Ca Sil cylinders can be lightly honed if the proper stone is used Ammco 3955 honing stones for use with the Ammco 3950 cylinder hone are suit able and can be ordered through most automotive supply stores or VST See General Information chapter for tool ordering information Port Chamfering Remove the sharp edges at the bottom and top of each port whenever boring or honing is performed Make sure there are no sharp edg
26. CHAPTER 3 ENGINES Torgue Specifications 3 1 Torque Patterns Cylinder Heads Cylinder Base 3 2 Torque Patterns Crankcase 3 3 Piston Cylinder Clearance Specifications 3 4 Engine Removal and Installation Typical 3 5 3 12 Disassembly Fan Cooled Twin Cylinder Series 3 13 3 17 Assembly Fan Cooled Twin Cylinder Series 3 18 3 21 Disassembly Liquid Twin Cylinder Fuji 3 22 3 25 Assembly Liquid Twin Cylinder Fuji 3 26 3 28 Disassembly Three Cylinder Monoblock 3 29 3 33 Assembly Three Cylinder Monoblock 3 24 3 37 Disassembly 440 500 Domestic Case Reed Twins 3 38 3 44 Assembly 440 500 Domestic Case Reed Twins 3 44 3 49 Disassembly 600 700 Domestic Case Reed Twins 3 50 3 56 Assembly 600 700 Domestic Case Reed Twins 3 57 3 61 Disassembly 700 800 Case Reed Fuji 3 62 3 64 Assembly 700 800 Case Reed Fuji 3 65 3 68 700 800 Fuji VES System 3 69 3 72 General Inspection Procedures 3 73 3 84 Cooling System Bleeding Procedures 3 85 Cooling System 500 500 RMK Classic Classic Touring Widetrak LX XLT Classic XLT Touring 3 86 Cooling System 600 XC SP 700 XC SP 3 87 Cooling System 600 RMK 700 RMK 700 SKS 3 88 Cooling System 440 XCR 3 89 Cooling System 500 XC SP 3 90 Cool
27. ES Three Cylinder Monoblock Assembly 1 2 Apply 3 Bond to upper crankcase half Lubricate oil pump drive gear Lightly grease seals and install on crankshaft with seal lip spring facing inward 3 Bond 1215 PN 2871557 120 Gram Tube Install crankshaft in upper crankcase NOTE Make sure seals and all locating anti rotation pins fit correctly in grooves and detent notches 3 Install bottom crankcase half Make sure anti rotation pins are aligned properly and torque bolts to specification found in beginning of this chapter Lubricate crankshaft main bearings through oil holes in upper crankcase Lubricate connecting rod big end bearing Lubricate pistons rings connecting rod small end bearing and cylinder before assembly Install pistons piston pins and C clips with end gap up or down NOTE Marking on piston faces flywheel Be sure C clips are fully seated in groove Apply a small amount of Loctite 515 gasket eliminator to base gasket ends and install gasket noting location of transfer port reliefs NOTE The sealant on base gasket faces up 10 98 3 34
28. Inc 3 5 10 98 ENGINES Engine Removal Engine Removal Typical Cont 5 Free recoil rope from chassis NOTE Be sure to tie a knot in recoil rope upon removal so rope doesn t wind up into recoil housing 6 Loosen clamps at carburetor mounting flange Pull carbs from adaptors and secure out of the way Note routing of all cables and hoses for reassembly 7 Disconnect oil pump control cable 8 Disconnect and plug oil supply line TIP A bolt or spare water trap plug can be used to plug the oil line from the oil reservoir 10 98 3 6 Polaris Industries Inc Engine Removal Typical Cont 9 Remove drive belt NOTE If drive clutch removal is necessary it may be done at this time Refer to Chapter 5 clutches 10 Remove exhaust system NOTE On triple pipe models mark pipe location to sim plify reassembly 11 Disconnect coolant supply hoses as necessary at the most convenient location on liquid cooled models Drain coolant into suitable container Polaris Industries Inc 3 7 ENGINES Engine Removal 10 98 ENGINES Engine Removal Engine Removal Typical Cont 12 Disconnect electrical connections from stator and starter motor where applicable 13 Remove two front and two rear engine mount bolts nuts that secure engine mount plate straps to chassis 14 Remove engine from chassis 10 98 3 8 Polaris Industries Inc ENGINES Engine
29. SN70 20 24 ft lbs 30 34 ft lbs 20 24 ft lbs 2 9 3 3 kgm 4 1 4 7 kg m 2 8 3 3 kgm Use high end of torque range on EC58PL Torque head bolts prior to torquing cylinder base nuts Apply loctite 242 108 in Ibs 1 24 kg m All 7 16 14 Engine Mount Strap Bolts 44 48 ft Ibs 6 0 6 63 kg m All 6mm Crankcase Bolts Polaris Industries Inc 3 1 Crankcase Crankcase Flywheel 8 mm 10 mm 60 65 ft Ibs 8 3 9 0 kgm 60 65 ft Ibs 8 3 9 0 kgm 90 ft Ibs 12 4 kgm 20 24 ft Ibs 30 34 ftlbs 20 24 ftlbs 26 80Ftlbs 55 ft lbs 2 8 3 3 kgm 4 2 4 7 kg m 2 8 3 3 kgm 3 6 4 15 kgm 7 4 kgm 10 98 ENGINES Torque Patterns Cylinder Heads Cylinder Base CYLINDER HEAD Domestic Twins 500 600 700 OKOLO LOO LT 20000 CYLINDER HEAD EC58PL CYLINDER HEAD EC45 50PL 6 A C0N20 006000 9 6 CYL BASE 500 600 700 Twins Fuji Liquid Twins Cylinder Head domestic 440 Cylinder Base 10 98 3 2 Polaris Industries Inc oa oe 9 2 0 CRANKCASE TWIN CYLINDER Fuji CRANKCASE 600 700 DOMESTIC TWINS Polaris Industries Inc ENGINES Torque Patterns Crankcase MoQ QO OQ OO CRANKCASE 3 CYLINDER OO BMY CRANKCASE 440 500 Domestic Twins 3 3 10 98 ENGINES Piston Cylinder Clearance Specifications Piston Measurement Whenever cylinders are honed or bore clearance is
30. ace all seals O rings and gaskets during disassembly Refer to pages 3 73 3 84 for general inspection proce dures Disassembly The photo at right shows a complete liquid cooled twin cylinder engine 1 Remove carburetors 2 Remove recoil housing and exhaust manifold 3 Remove water pump and starter recoil cup with water pump drive pulley and flywheel nut Note position of shim washers for pulley alignment upon reassembly 4 Install flywheel puller Use all flywheel bolt holes Do no install puller bolts more that 5 16 7mm into flywheel or stator damage may result Flywheel Puller PN 2871043 10 98 3 22 Polaris Industries Inc ENGINES Liquid Twin Cylinder Fuji Disassembly Cont 5 Mark stator plate and crankcase for reference when reassembling the engine MARK PLATE AND CASE 6 Using an impact screwdriver remove stator screws 7 Remove oil pump oil pump feed lines and banjo bolts from cylinder Clean and inspect all components 8 Remove cylinder head Polaris Industries Inc 3 23 10 98 ENGINES Liquid Twin Cylinder Fuji Disassembly Cont 9 Remove head gasket Note position of head gasket inlet and outlet hole sizes for reference during reassembly 10 Remove cylinder 11 Remove C clip retainers from piston as shown 12 Using piston pin puller remove piston pin from piston as show
31. bolts in proper sequence Refer to specifications in the beginning of this chapter 700 Cylinder Base 12 Torque head bolts in proper sequence Refer to specifications in the beginning of this chapter 700 Cylinder Head Polaris Industries Inc 3 59 10 98 ENGINES 600 700 Domestic Case Reed Twin Assembly Cont 13 Reassemble water pump carefully installing seal 14 Install crankcase seal to ignition water pump housing from inside toward outside until bottomed on housing Spring and seal lip must face inward toward crankshaft 15 Apply 3 Bond sealant to pump housing crankcase mating surface and carefully install onto crankcase Tighten water pump to engine hose clamp and torque bolts to specification Ignition Water Pump Housing Torque 22 Ft Ibs 3 04kgm 16 Align timing marks and install stator 10 98 3 60 Polaris Industries Inc Assembly Cont 17 Install flywheel and torque flywheel nut to specification found in the beginning of this chapter Flywheel Holder PN 8700229 18 Install water pump belt and recoil hub NOTE See 600 700 domestic twin water pump belt installation in chapter 2 Maintenance for correct belt installation a Recoil Hub Bolt Torque 96 108 in Ibs 1 11 1 25 kg m 19 Install recoil cover and oil pump Make sure oil pump drive slot mates properly with water pump shaft 20 Install reed valve reed stuffer and reed cover
32. checked it is important to measure piston diameter properly to arrive at its major dimension Measurements should be taken with piston at room temperature and at right angles to the pin as shown Determine the largest diameter within this area and refer to the chart below for clearance specifications Cylinder bore must be straight and concentric Refer to honing information outlined in this chapter for specific procedures Refer to the specifications section in chapter 1 for Target Clearance when re boring cylinder or Service Limit specifications to determine if piston requires replacement Piston to Cylinder Clearance Refer to specifications in chapter 1 for specific models Piston Ring Installed Gap Refer to specifications in chapter 1 for specific models FUJI ENGINES Measure 1 2 12 7mm up from bottom of skirt DOMESTIC ENGINES Measure 3 8 10 0mm up from bottom of skirt Important Always verify piston to cylinder clearance and piston ring installed gap prior to assembling an engine 10 98 3 4 Polaris Industries Inc Engine Removal Typical 1 On some models it may be necessary to remove the hood for earier access to engine components or to prevent damage 2 Disconnect battery ground from battery if applicable Shut off fuel 3 Remove fuel pump or CDI from airbox if applicable 4 Remove airbox ENGINES Engine Removal Ground Cable Polaris Industries
33. cooling system overheats Incorrect main jet Incorrect timing Incorrect spark plug Water pump belt loose or broken Cooling restriction Inadequate snow for cooling ice and or marginal conditions Battery will not Check for faulty connections charge battery Check alternator output equipped mod Check diodes rectifier els only Sulphated battery Battery electrolyte overfilled or low Refer to alternator testing in chapter 9 electrical 10 98 3 94 Polaris Industries Inc ENGINES Troubleshooting PROBLEM PROBABLE CAUSE Lights don t Engine must be running work Check wiring harness connector Check for burned out bulbs Check wiring for shorts or loose connections Disconnect taillight if headlight works short is in taillight wiring or taillight Unit fails to pro Check belt center distance pel itself Check clutch Check chain Check drive sprocket assembly Track frozen or stuck Track wears un Check tension evenly Check for proper alignment Check for loose bent or broken suspension parts Chaincase Check oil level overheating Check chain tension Check track assembly Polaris Industries Inc 3 95 10 98
34. each fiber reed for white stress marks or missing material Replace if necessary V E S Removal 440 2 Pull back cover retainer clip while holding the cover in place 3 Remove cover and return spring 2 Slide Clip 4 If the spring stays in the cover hold the cover with spring facing toward you Rotate spring in Retainer Clip a counterclockwise direction while pulling outward on the spring Do not distort the spring Cover upon removal CAUTION Do not attempt to remove the plastic Rotate to remove ZLS valve piston at this time The bellows must first be from cover N removed from the piston or damage may occur to the bellows or piston 5 Remove two 5mm hex screws from valve housing Au 6 Note location of TOP marks on housing and Align TOP marks p exhaust valve Lift entire valve assembly from cylinder along with gasket B Housing Bolts Appl Loctite 242 blue Torque 108 in Ibs O ring 1 24 kg m 10 98 3 38 Polaris Industries Inc ENGINES 440 500 Domestic Case Reed Twin Disassembly Cleaning Inspection VES 440 XCR 1 Carefully remove the fastener strap in the area shown Use care to avoid cutting the bellows 2 Fold back upper edge of bellows to expose low er edge of piston Remove Bellows Lower Clamp 3 Hold exhaust valve securely and remove piston by turning the 10mm hex counterclockwise 4 Slide exhaust valve out of housing 5 Remove O ring fr
35. er piston Torque cylinder base nuts to specification found in the beginning of this chapter 10 98 3 66 Polaris Industries Inc ENGINES 700 800 Case Reed Fuji Assembly Cont 11 Install new head and head cover O rings 12 Install heads and torque to specification found in beginning of this chapter Reed Pedal Reed Valve Inspection Clearance 015 Exaggerated for illustration ji 38 mm max 13 Measure air gap between fiber reed and reed block as shown The air gap should not exceed 015 4 mm If clearance is excessive DO NOT attempt to reverse the reeds to reduce the air gap Always replace them if damaged Check each fiber reed for white stress marks or missing material Replace if necessary Reed Air Gap Maximum 015 4 mm 14 Install reed cages and carburetor mounting flanges Polaris Industries Inc 3 67 10 98 ENGINES 700 800 Case Reed Fuji Assembly Cont 15 Install oil pump drive gear in correct sequence 16 Check oil pump drive gear end play See adjustment in General Inspection Procedures 17 Install oil pump 18 Position stator plate at previously marked position and secure in place 19 Torque flywheel nut to specification found in beginning of this chapter Install new O ring on water pump and grease lightly Install pump recoil cup and belt Flywheel Holder PN 8700229 20 Adjust tension on water pump belt by loosening moun
36. es IMPORTANT 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 oi the bore immediately with Polaris Premium 2 Cycle Lubricant NOTE Always check piston to cylinder clearance and piston ring installed gap after boring honing is complete 10 98 3 74 Polaris Industries Inc Crankcase Inspection Bearing Fit Any time crankshaft bearing failure occurs and the case is to be reused Polaris recommends checking the bear ing fit into the case halves using the following procedure 1 With case halves cleaned press a replacement bearing into each of the main bearing journals to determine a basic amount of press fit NOTE Do a comparison check of all journals by manually forcing the bearing into the bearing seats noting if any are noticeably loose or tight Normal hand installation will be an indication of the recommended interference fit If the bearing falls out of the case when the case is inverted or if the crankcase bearing surface is severly galled or damaged the case should be replaced Crankcase Bearing Interference Fit C 3 0006 015mm C 4 001
37. es are manufactured by such companies as Sunnen Products Company of St Louis Missouri and Ammco Tools Inc of North Chicago Illinois Shown at right is the Ammco No 3950 hone This hone has roughing and finishing stone sets available to service engines with cylinder bores up to 75mm in diameter De glazing If cylinder wear or damage is minimal hone the cylin der lightly with finish stones following the procedure outlined on page 3 74 Honing To Oversize If cylinder wear or damage is excessive it will be nec essary to oversize the cylinder using a new oversize piston and rings This may be accomplished by either boring the cylinder and then finish honing to the final bore size or by rough honing followed by finish honing NOTE Portable rigid hones are not recommended for oversizing cylinders cylinder boring and finish hon ing The use of an arbor type honing machine is rec ommended For oversize honing always wet hone using honing oil and a coarse roughing stone Measure the new piston at room temperature see piston measurement and rough hone to the size of the piston or slightly larger Always leave 002 003 05 07 mm for finish hon ing Complete the sizing with fine grit stones to provide the proper cross hatch finish and required piston clearance EXAMPLE OF CROSS HATCH PATTERN Inspect cylinder for taper and out of round Taper or out of round on the finished bore should not exceed 0004
38. ge or blockage npg 11 Remove crankshaft seal from housing by driving seal to inside of housing Replace seal if removed 12 Remove water pump cover bolts 10 98 3 52 Polaris Industries Inc ENGINES 600 700 Domestic Case Reed Twin Disassembly Cont 13 Remove impeller nut 14 Slide shaft out back side 15 Inspect bearings Replace if necessary Replace mechanical seal using the special tools listed below Use the seal press to install a new mechanical seal in cover with spring sleeve toward impeller housing Install seal guide over end of shaft and apply a light film of grease to seal guide Carefully install shaft and bearings in cover Assemble 10x14mm washer impeller washer and nut Torque impeller nut to specification Water Pump Mechanical Seal Installation Tool 1999 600 700 domestic engines 8 9mm PN 2872389 Impeller Nut Torque 10 ft Ibs 1 38 kg m Polaris Industries Inc 3 53 10 98 ENGINES 600 700 Domestic Case Reed Twin Disassembly Cont 16 Remove reed cover reed stuffers and reeds Reed Valve Inspection 17 Measure air gap between fiber reed and reed block as shown The air gap should not exceed 015 4 mm If clearance is excessive DO NOT attempt to reverse the reeds to reduce the air gap Always replace them if damaged Check each fiber reed for white stress marks or missing material Replace if necessary Reed Pedal Clearance
39. hapter for oil pump adjustment procedure 8 Install carburetors and tighten clamps Make sure hoses and cables are routed correctly 9 Connect oil lines to carburetors 10 98 3 10 Polaris Industries Inc Engine Installation Typical Cont 10 Install coolant hoses where applicable Make sure hoses are routed properly and hose clamps are positioned and tightened securely 11 Route and install recoil rope to chassis 12 Install starter and starter cables electric star models 13 Install exhaust system in reverse order o disassembly ENGINES Engine Installation Polaris Industries Inc 3 11 10 98 ENGINES Engine Installation Engine Installation Typical Cont 14 Install hood if previously removed 15 Install airbox 16 Secure fuel pump and CDI box 17 Fill cooling system liquid models with Polaris Premium Antifreeze 60 40 premix Polaris Premium Antifreeze 60 40 premix Quart PN 2871534 Gallon PN 2871323 18 Add a full tank of premix fuel 40 1 to fuel tank 19 Start engine and check operation Bleed cooling system on liquid models See Cooling System Bleeding Procedures in this chapter 10 98 3 12 Polaris Industries Inc ENGINES Fan Cooled Twin Cylinder NOTE Inspect all parts for wear or damage during disassembly Replace all seals O rings and gaskets during disassembly Refer to pages 3 73 3 84 for general inspection proce dures Engine Disasse
40. horted or open Ignition switch shorted contaminated with moisture Auxiliary switch shorted or contaminated with moisture Engine idles but Restricted fuel flow air flow no acceleration Clogged main jet Timing Clutching Engine not running on all cylinders Engine runs but Clogged fuel filter fails to reach Incorrect track tension maximum RPM Incorrect main jet Throttle slides not fully open Chain too tight Clutching Excessive driveline friction HiFax overheating Engine not running on all cylinders Engine runs but Incorrect air mixture setting fails to idle Throttle stop screw incorrectly adjusted Restricted pilot jet Low compression Tight belt Piston damage Enricher plunger not seating properly Engine runs Enricher plunger are not seating properly but overloads Fuel pump diaphragm is ruptured caused by engine backfiring with fuel Carburetor slides are not synchronized Main jet too large Needie and seat not seating properly Incorrect float level Check reed valve condition Carburetion and Verify all tune up adjustments carb sync oil pump adjustment pilot screw setting spark plug type plug fouling and gap venting for carbs proper jetting for altitude and temperature belt tension clutch operation If tune up items are correct check float level jet needle position jet needle wear inlet needle and seat wear spark quality etc Engine runs but Coolant level low or air in
41. ies Inc ENGINES General Inspection Procedures Crankshaft Truing Lubricate the bearings and clamp the crankshaft securely in the holding fixture On three cylinder crankshatts straighten one of the ends Magneto or PTO and then straighten the center section Place the center section in the holding fixture and then straighten the remaining end If truing the crankshaft requires striking with a ham mer always be sure to re check previously straightened areas to verify truing Refer to the illustrations below Crankshaft Alignment Fixture PN 2870569 NOTE The rod pin position in relation to the dial indi cator position tells you what action is required to straighten the shaft 5 To correct a situation like the one shown in the illustration at right strike the shaft at point A with a _ HIGH 004 1mm brass hammer A A HIGH 004 1mm 8 NOTE The rod pin position in relation to the dial indi SUPPORT CRANKSHAFT cator position tells you what action is required to AT THESE TWO BEARINGS straighten the shaft 6 To correct a situation like the one shown in the illustration at right squeeze the crankshaft at HIGH 002 05mm HIGH 005 13mm A point A Use tool from alignment kit 7 If the crank rod pin location is 180 from the dial indicator opposite that shown above it will be HIGH 002 05mm necessary to spread the crankshaft at the A position as shown in the illustration
42. ing System XLT Special 3 91 Cooling System 700 800 XCR 3 92 Recoil Starter Spring Replacement 3 93 Troubleshooting 3 94 3 95 ENGINES Torque Specifications When tightening bolts nuts or screws a torque pattern should be followed to ensure uniform equal tension is applied to all fasteners Proper torque application prevents fasteners from loosening or breaking in critical service It also minimizes wear and eliminates premature or needless repair costs Following uniform torque application sequence patterns ensures optimum performance from precision machined close tolerance assemblies The most common units of torque in the English system are ft Ib and in Ib In the Metric system torque is commonly expressed in units of kg m or Nm Newton Meters Multiply foot pounds by 1383 to obtain kg m Move decimal point one place to the right to obtain Nm from kg m Cylinder Head Cylinder Base Nuts 24 28 ft Ibs 3 3 3 9 kgm 18 19 ft Ibs 2 5 2 65 kgm Fan Cooled Twin Cylinder EC50PL EC58PL EC70PL EC79PL 17 18 ft Ibs 23 25 ft Ibs 2 2 2 3 kgm 3 2 3 5 kgm 17 18 ft Ibs 23 25 ft Ibs 2 2 2 3 kgm 3 2 3 5 kgm 24 28 ft Ibs 3 3 3 9 kgm 10mm 24 26 ft Ibs 3 3 3 6 kgm 8mm 17 20 ft Ibs 2 4 2 8 kgm SN44 SN50 SN60
43. k the valve and valve bore in the cyl inder for carbon deposits and clean if neces Sary Polaris Industries Inc 3 71 10 98 ENGINES 700 800 Case Reed Fuji V E S Assembly 700 800 XCR 1 Replace gasket and insert exhaust valve into valve housing 2 Install washer beveled side out 3 Install bellows and valve cap 4 Install spring valve cover and adjuster nut 5 Set adjuster nut according to rider preference Refer to page 3 69 10 98 Bevel side out Polaris Industries Inc ENGINES General Inspection Procedures Cylinder Honing The cylinder bore must be de glazed whenever new piston rings are installed A light honing with fine stones removes only a very small amount of material A proper crosshatch pattern is important to provide a surface that will hold oil and allow rings to seat properly If the crosshatch is too steep oil retention will be reduced A cross hatch angle which is too shallow will cause ring vibration poor sealing and overheating of the rings due to blow by and reduced contact with the cylinder wall Service life of the pistons and rings will be greatly reduced Cylinder Hone Selection Selecting a hone which will straighten as well as re move material from the cylinder is very important Honing a cylinder with a spring loaded glaze breaker is never advised Polaris recommends using a rigid type hone which also has the capability of oversizing These hon
44. lts and separate crankcase halves 11 Inspect crankcase and crankshaft as outlined in general inspection procedures 12 Clean crankcase thoroughly to remove all grease oil dirt and old sealant 10 98 3 64 Polaris Industries Inc ENGINES 700 800 Case Reed Fuji Assembly 1 Grease oil pump drive gear and end seals 2 Position anti rotation pins with relief in case 3 Apply a light film of 3 Bond 1215 to crankcase and reassemble halves 3 Bond 1215 PN 2871557 120 Gram Tube Polaris Industries Inc 3 65 10 98 ENGINES 700 800 Case Reed Fuji Assembly Cont 4 Install bolts and torque to specifications and pattern found in beginning of this chapter 5 Install piston pin bearings 6 Install piston with arrow p gt toward flywheel 7 Install C clip retainers using tool NOTE The C clip opening should be in the up or down position Be sure C clips are properly seated in groove C Clip Retainer Installation Tool PN 2870773 8 Lightly oil rings and cylinder NOTE Keystone ring bevel must be up Marking near ring end gap faces upward Straight Edge Piston Ring Cutaway 9 Install new base gaskets with sealant facing where applicable Keystone Piston Ring 10 Carefully compress rings and install cylinder ov
45. mbly The photo at rignt shows a complete fan cooled twin cyl inder engine 1 Remove carburetors 2 Disconnect oil pump feed lines and remove oil pump 3 Remove carburetor adaptors f 4 Remove air shrouds NOTE There may be gaskets between shroud and cylinder Polaris Industries Inc 3 13 10 98 ENGINES Fan Cooled Twin Cylinder Engine Disassembly Cont 5 Note position of shroud retainer mounts on cylinder heads These must be in the same position for reassembly 6 Remove recoil fan housing 7 Remove recoil drive hub 8 Hold flywhee with tool PN 8700229 Remove flywheel retaining nut Flywheel Holding Too PN 8700229 10 98 3 14 Polaris Industries Inc ENGINES Fan Cooled Twin Cylinder Engine Disassembly Cont 9 Using flywheel puller remove flywheel Use all available puller bolt holes on flywheel Do not install puller bolts more than 5 16 7mm into flywheel threads or stator damage may result Flywheel Puller PN 2871043 10 Mark stator plate and crankcase for reference upon reassembly Remove stator plate 11 Remove two bolts securing inner and upper shroud Remove upper sh
46. n Piston Pin Puller PN 2870386 10 98 3 24 Polaris Industries Inc ENGINES Liquid Twin Cylinder Fuji Disassembly Cont 13 Remove crankcase bolts NOTE Refer to General Inspection Procedures on pages 3 73 3 84 for engine component inspection i e crankshaft and crankcase inspection piston clearance oi pump drive gear end play etc Polaris Industries Inc 3 25 10 98 ENGINES Liquid Twin Cylinder Fuji Assembly Prior to assembly refer to page 3 81 and check ring end gap and piston to cylinder clearance 1 Grease crankshaft end seals and oil pump drive gear area as shown Seals should be installed with spring and lip facing inward toward crankshaft 2 Turn bearing until anti rotation pins are positioned in the proper location 3 Apply 3 Bond sealant to crankcase halves 3 Bond 1215 PN 2871557 120 Gram Tube 4 Torque crankcase bolts following sequence outlined in beginning of this chapter Lubricate crankshaft main bearings through access holes 5 Install pistons with F mark or arrow p gt toward flywheel 6 Install C clip using installation tool PN 2870773 7 Install new base gasket AWA 8 Lubricate rings and pistons with two stroke oil Install rings with letter mark or beveled side facing upward if Fe 10 98 3 26 Polaris Industries Inc ENGINES Liquid Twin Cylinder Fuji Assembly Cont 9
47. ndard pressure cap will not allow the recovery system to function properly If the cap should need replacement install the correct Polaris cap with the same pressure rating Refer to the appropriate parts manual NOTE Always use Polaris premium antifreeze 60 40 premix Bleed system at specified RPM or air will remain trapped in system which may result in overheating Filling and Bleeding Procedure Lift Lock Lever To Bleed If the cooling system should become low in the reservoir tank and or filler neck the system should be bled of any trapped air using one of the following procedures depend ing on model Fuji except 700 800 XCR rs ai 1 Elevate front end of machine approximately 10 25 cm j Caution 2 Fill coolant reservoir to indicated maximum level line Increase RPM 3 Remove pressure cap and slowly add coolant until slowly when lever coolant level iseven with top of filler neck Install lock is up to avoid pressure cap and lift lever d loss of coolant 4 Install the pressure cap with the lever lock up in its release position and run the engine at low idle RPM 600 RPM 100 to allow all air to purge and prevent trapped air which can lead to overheating and engine damage Reset idle to specs after bleeding System is properly Bleed Screw bled when no air bubbles are visible in overflow line when RPM is increased slightly Lock pressure cap and fill the coolant reservoir to proper level 700 and 80
48. om exhaust valve shaft Housing Piston do not attempt to remove piston from ex haust valve until upper clamp and bellows are removed from piston Gasket 6 Compress lower spring clamp and remove bel X lows and clamp O ring 7 Clean O ring and bellows in warm water and mild detergent Inspect bellows for holes dis 3 tortion or damage Replace if necessary In spect O ring for damage g ___Hold exhaust valve 8 Clean all other parts with solvent Be sure all parts are thoroughly clean 9 Inspect the actuator port in cylinder and valve housing Be sure it is clear and not obstructed by debris or carbon 10 Carbon deposits can be removed from valve with a Scotch Brite pad or similar soft abra sive brush Lubricate exhaust valve with Polaris Premium Gold 2 cycle engine lubricant Install valve in cylinder and move it through the entire travel range to check for free movement without bind ing If the valve sticks anywhere in the travel range check the valve and valve bore in the cyl inder for carbon deposits and clean if neces sary 1 k Polaris Industries Inc 3 39 then remove pisto 10 98 ENGINES 440 500 Domestic Case Reed Twin V E S Assembly 440 XCR 1 2 Install lower clamp over small end of bellows Assemble dry Install bellows on housing Be sure bellows is completely seated in groove and install clamp Place a new o ring and gasket on exhaust valve Inser
49. oved 3 Ifthe spring stays in the cover hold the cover with spring facing toward you Rotate spring in a counterclockwise direction while pulling outward on the spring Do not distort the spring upon removal 4 With a 10 mm wrench loosen exhaust valve cap and remove NOTE Top nut is secured to valve with adhesive Removing top nut may damage threads on valve 5 Remove exhaust valve remaining components NOTE 700 XCR valves are marked 70 UP and 800 XCR valves are marked 79 UP Upon installation be sure this marking faces upward 10 98 3 70 Polaris Industries Inc ENGINES 700 800 Case Reed Fuji Disassembly Cleaning Inspection VES 700 800 XCR 1 Clean O ring and bellows in warm water and mild detergent Inspect bellows for holes dis tortion or damage Replace if necessary In spect O ring for damage 2 Clean all other parts with solvent Be sure all parts are thoroughly clean 3 Inspect the actuator port in cylinder and valve housing Be sure it is clear and not obstructed by debris or carbon 4 Carbon deposits can be removed from valve with a Scotch Brite pad or similar soft abra Clean with solvent Y sive brush amp NS wa 5 Lubricate exhaust valve with Polaris Premium Gold 2 cycle engine lubricant Install valve in cylinder and move it through the entire travel range to check for free movement without bind ing If the valve sticks anywhere in the travel range chec
50. p shaft out of lower case half from front water pump side to rear oil pump side Note location washers on the shaft Polaris Industries Inc 3 43 10 98 ENGINES 440 500 Domestic Case Reed Twin Disassembly Cont 21 Press front bushing oil seal and mechanical seal out of lower crankcase using a suitable soft drift from the oil pump rear side Be careful not to damage bushing Assembly 1 Insert bushing into case on water pump side using weep hole to align hole for retaining pin Press in until firmly seated in case Install retaining pin Tap in until seated in bushing NOTE If front bushing is replaced it may be necessary to drill a retaining pin hole in the new bushing If there is no hole in the bushing e Install bushing in crankcase as described above e Remove the retaining pin from lower crankcase e Using the retaining pin hole as a guide carefully drill a hole in the new bushing to the same depth and diameter as the hole in the old bushing Be careful not to enlarge the retaining pin hole e Install new retaining pin Install oil seal with spring facing outside of crankcase toward you until seated against bushing Lubricate and install washer on pump shaft water pump end Install shaft with washer through bushing and oil seal from the oil pump side of case Be sure spring stays in position on seal lip Install remaining washer on shaft Lubricate and install rear bushing
51. pring facing inward toward crankshaft Place crankshaft in upper crankcase half Make sure seal and PTO bearing retainer fit properly into grooves 4 Install bottom crankcase half and insert crankcase bolts Torque to specification in proper sequence shown in beginning of this chapter Lubricate crankshaft bearings though oil holes in upper crankcase 5 Install pistons with arrow p gt on piston facing flywheel Install C clips securely in piston groove 6 Lubricate rings and pistons with two stroke oil Install rings with letter mark or beveled side facing upward 7 Install base gasket with adhesive sealant strip facing up if applicable 10 98 3 18 Polaris Industries Inc ENGINES Fan Cooled Twin Cylinder Engine Assembly Cont 8 Lubricate cylinder with two stroke oil and install onto piston while compressing piston rings by hand Be sure ring end gap is centered over locating pin or ring damage may occur NOTE Use a piston support block to help hold piston and prevent piston damage during assembly Piston Support Block PN 2870390 9 Torque cylinder base bolts to specification found in the beginning of this chapter cin aeeesiatiee eee teen esseasete eae Pea PEE 10 Install head gasket with wide side of fire ring facing down narrow side up 11 Install cylinder heads and torque
52. roud 12 Loosen and remove all bolts securing cylinder heads to cylinder Remove heads Polaris Industries Inc 3 15 10 98 ENGINES Fan Cooled Twin Cylinder Engine Disassembly Cont 13 Remove cylinder base nuts and cylinders NOTE Refer to General Inspection Procedures for cylinder inspection 14 Support piston to prevent damage Remove piston c clip 15 Remove piston pin and remove pistons Refer to General Inspection Procedures in this chapter Piston Pin Puller PN 2870386 16 Remove engine mount plate or straps and remove all crankcase bolts 10 98 3 16 Polaris Industries Inc ENGINES Fan Cooled Twin Cylinder Engine Disassembly Cont 17 Separate crankcase halves 18 Measure connecting rod side clearance Refer to General Inspection section for measurement procedure Connecting Rod Side Clearance 012 016 30 40 mm 19 Refer to General Inspection section for crankshaft inspection procedure Polaris Industries Inc 3 17 10 98 ENGINES Fan Cooled Twin Cylinder Engine Assembly 1 Clean all engine components thoroughly in a solvent tank Blow dry with compressed air 2 Apply 3 Bond sealer to top half of crankcase Lubricate oil pump drive gear 3 Bond 1215 PN 2871557 120 Gram Tube 3 Lightly grease seals and install on crankshaft on crankshaft with lip s
53. s the malfunction is one of the following e Inline filter blocked e Air not bled from oil pump e Feed lines leaking e Oj tank vent restricted or kinked e Defective pump 10 98 3 82 Polaris Industries Inc Oil Pump Bleeding ENGINES General Inspection Procedures The oil pump must always be bled following any service to the injector system or engine which allows the loss of oil and subsequent entrapped air during reassembly 1 2 Fill oil reservoir with Polaris injector oil Loosen bleed screw A After a short time oil should flow from beneath the screw head to indicate the pump is free of air Tighten bleed bleed screw securely Oil Pump Adjustment All Models NOTE Adjust carburetor synchronization idle speed and throttle cable free play before adjusting oil pump 1 2 Stop engine With throttle in its idle position the pump lever index mark A must align with the pump housing boss index mark B On domestic 500 cc engines align the dot on the pump arm to the mark on pump Loosen lock nuts on cable housing sleeve and vary cable housing length as required until proper marks are aligned NOTE Verify pump lever moves upon initial throttle opening Oil Pump Bushing End Play Adjustment Fuji If the oil pump crankcase or any pump drive component is replaced inspect the drive gear bushing end play us ing the following procedure L Assemble oil pump drive gear assembly Be s
54. se off to wear strip coolers COOLANT ENGINE NOTE When leak testing cooling system system BOTTLE pressure should not exceed 2 Ibs less than cap pres sure Refer to filling and bleeding procedure on page CENTER 3 85 TUNNEL STRIP COOLERS COOLER COOLER Polaris Industries Inc 3 89 10 98 ENGINES Cooling System 500 XC SP Hose rear wear strip coolers Hose tee to bottle Hose tee to center cooler LY Hose close off to wear Ly strip cooler Hose tee out S amp S to pump in a f SK NOTE When leak testing cooling system system pressure should not exceed 2 Ibs less than cap pres CENTER sure Refer to filling and bleeding procedure on page 3 85 COOLER TUNNEL STRIP COOLERS 10 98 3 90 Polaris Industries Inc ENGINES Cooling System XLT Special Note Filter is located before the check valve Coolant flows from tank through filter then check valve to water pump Check valve Hose engine out to filler Hose center cooler to pump NOTE When leak testing cooling system system pressure should not exceed 2 Ibs less than cap pres sure Refer to filling and bleeding procedure on page 3 85 CENTER COOLER LH COOLER RH COOLER Polaris Industries Inc 3 91 10 98 ENGINES Cooling System 700 800 XCR Hose pump to surge tank lower Hose tee to rear cooler v q Hase surge tank to rear cooler Hose brake 9 S cooler to tee CO
55. t exhaust valve in housing with TOP marks aligned Both the valve housing and valve are marked with TOP Apply Loctite 242 to threads of exhaust valve and install the piston Hold exhaust valve and torque piston to 25 in Ibs 28 kg m Install valve assembly in cylinder with TOP marks on valve and housing facing up Apply Loctite 242 blue to housing bolt threads Install and torque bolts to 108 in Ibs 1 24 kg m Fit upper sealing edge of bellows into groove on piston Secure the bellows by installing the fastener strap NOTE Move the valve up and down in the full travel range and check for smooth op eration If the valve binds in any spot check the bellows to be sure it is not twisted on the piston Install spring and cover Be sure spring is prop erly positioned on the piston and in the cover 10 98 3 40 Nw 7 Align TOP marks Housing Bolts App 4 Loctite 242 blue Torque 108 in Ibs 1 24 kg m O ring 1 Compress and Hold Cover 2 Slide Clip Up Polaris Industries Inc ENGINES 440 500 Domestic Case Reed Twin Disassembly Cont 7 Remove cylinder head cover and inspect O rings and sealing surfaces for damage or debris Use new O rings upon assembly 8 Remove cylinder base nuts Note location of acorn nuts on exhaust side where applicable 9 Carefully remove cylinders while supporting pistons and connecting rods to prevent
56. ting bolts applying tension and re tightening bolts Install recoil housing and belt guard 1 8 3 16 3 4 cm 10 98 3 68 Polaris Industries Inc V E S Adjustment 700 800 XCR The RPM at which the exhaust valves open and close can be tuned by turning the spring adjuster in or out for the desired valve characteristics 1 Turning spring adjuster in e Creates more spring pressure Allows exhaust valve to open at slower rate e For applications such as drag racing 2 Turning spring adjuster out e Creates less spring pressure e Allows exhaust valve to open at faster rate For applications such as trail riding Riders can fine tune the VES to suit their riding con ditions and power delivery characteristics Base setting is with adjuster screw flush with housing CAUTION Do not turn spring adjuster too far The spring adjuster is turned out to its maximum when the adjuster is flush with top of housing Adjuster usa O TS Valve cover Spring Valve x Bellows ware SS KA PS D Bie ee Valve housing Dowel pin Gasket Polaris Industries Inc 3 69 ENGINES 700 800 Case Reed Fuji 10 98 ENGINES 700 800 Case Reed Fuji V E S Removal 700 800 XCR t Remove two mounting bolts Remove exhaust valve assembly from cylinder 2 Remove four cover bolts cover and return spring CAUTION Valve is spring loaded Hold cover in position until all bolts are rem
57. trained Polaris service technicians in a properly equipped shop Piston Pin Needle Bearing Inspection 1 Clean needle bearing in solvent and dry with compressed air 2 Inspect needle cage carefully for cracks or shiny spots which indicate wear Replace needie bearings if worn or cracked and always replace them if piston damage has occurred 3 Visually inspect piston pin for damage discoloration or wear Run your fingernail along the length of the pin and replace it if any rough spots galling or wear is detected Connecting Rod Small End Inspection 1 Clean small end of connecting rod and inspect inner bore with a magnifying glass Look for any surface irregularities including pitting wear or dents 2 Run your fingernail 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 Rotate pin slowly and check for rough spots or any resistance to movement Slide pin back and forth through bearing while rotating and check for rough spots 4 With pin and bearing centered in rod twist ends back and forth in all directions to check for excessive axial play Pull up and down evenly on both ends of pin to check for radial play 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 10 98 3 76 Polaris Industr
58. ure the bushing is fully seated in the crankcase 2 Measure distance from oil pump mounting surface to bushing Call this measurement A Polaris Industries Inc 3 83 10 98 ENGINES General Inspection Procedures Oil Pump Bushing End Play Adjustment Fuji continued 3 Measure distance from oil pump mounting flange surface to end of seal flange as shown Call this measurement B 4 Subtract measurement B from A to determine total bushing end play 5 Measure thickness of existing shims and subtract from total bushing end play determined in step 3 6 Add or subtract shims as required to provide specified end play 7 Lightly grease a new O ring and install it on the pump Install pump engaging slot in shaft with drive gear Apply Loctite 242 to bolts and torque evenly to 78 in Ibs 9 kg m End Play 008 016 203 406 mm Optional Shims PN 3083671 006 15mm PN 3083672 012 3mm PN 3083673 024 6mm Oil Pump Mounting Bolt Torque 242 Blue 78 in Ibs 9 kg m 10 98 3 84 Polaris Industries Inc ENGINES Cooling System Bleeding Procedures WARNING Never remove the pressure cap when the engine is warm or hot If the pressure cap is to be removed the engine must be cool Severe personal injury could result from steam or hot liquid Use of a non sta
59. ward toward upper case half Polaris Industries Inc 3 57 10 98 ENGINES 600 700 Domestic Case Reed Twin Assembly Cont 4 If studs were removed or new crankcase installed apply Loctite 242 to threads of studs and screw in until bottomed Tighten securely 5 Measure installed length of stud bolt This is the length necessary to allow cylinder installation Lower Crankcase Stud Height 121 124 mm 4 76 4 88 from crankshaft parting line 6 Install crankcase halves together Torgue bottom crankcase bolt to specification in the proper seguence found in the beginning of this chapter 7 Install new O rings on water manifold Grease O rings and install manifold 8 Install pistons and rings Make sure C clips are firmly seated in grooves NOTE Keystone ring bevel must be up Marking near ring end gap faces upward Straight Edge Piston Ring Cutaway Keystone Piston Ring 10 98 3 58 Polaris Industries Inc ENGINES 600 700 Domestic Case Reed Twin Assembly Cont 9 Lubricate pistons rings upper rod bearing and cylinders with two stroke oil and install cylinders Align ring end gaps with locating pins and compress rings Install cylinder carefully with a gentle front to rear rocking motion Loosely install cylinder nuts 10 Install new cylinder head O ring and install cylinder head Make sure O ring is properly seated in groove 11 Torque cylinder base
60. wist or force cylinder during installation 26 Install new cylinder head O rings and install cylinder head Make sure O rings are properly seated in grooves Apply a light film of grease to hold O rings in place if necessary up Straight Edge Piston Ring Cutaway Keystone Piston Ring 10 98 3 46 Polaris Industries Inc ENGINES 440 500 Domestic Case Reed Twin Assembly Cont 27 Install new cylinder head cover O rings and install cylinder head cover Make sure O rings are properly seated in grooves Apply a light film of grease to hold O rings in place if necessary 28 Loctite 242 to threads of head bolts and install 29 Torque head bolts to specification outlined in beginning of this chapter in proper sequence HO 00 00 DO Cylinder Head 30 Torque cylinder base nuts outlined in beginning of this chapter in proper sequence OO OO DO Cylinder Base 31 Install washers and water pump impeller as shown and torque nut to 10 ft lbs 1 38 kg m Washer 10 3x14x1mm 10 ft lbs Impeller Nut Torque 10 Ft Ibs 1 38 kgm Mechanical Washer Seal 325x 75x 063 Polaris Industries Inc 3 47 10 98 ENGINES 440 500 Domestic Case Reed Twin Assembly Cont 32 Install water pump cover with new gasket Water Pump Cover Bolt Torque 9 Ft Ibs 1 25 kgm 33 Install new exhaust manifold gaskets and manifold Exhaust Manifold
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