Snowmobile Polaris (2006 year). Manual - part 32

6.14

ENGINE

8.

Remove the snap ring from the case.

9.

Remove the cross shaft and bearings.

700/900 WATER/OIL PUMP CROSS SHAFT 
ASSEMBLY

NOTE:  Cross shaft assembly (PN) comes with the 
shaft, gear, seal, snap ring, mechanical seal.

1.

Insert the cross shaft and bearings into the crankcase.

2.

Install the snap ring into the groove in the crankcase.

3.

Press in the oil seal into the crankcase.

4.

Place the mechanical seal onto the cross shaft so that the
blue sealant is facing the crankcase.

5.

Press the mechanical seal into the case with the seal
installation tool (PN PW-46986).

6.

Install the impeller, washer, and nut.

7.

Torque the impeller nut to 120 in-lb (14Nm).

8.

Place o-ring, and cover on to the upper case.

9.

Torque the cover fasteners to 108 in-lb (12Nm).

700/900 RECOIL/STATOR DISASSEMBLY

1.

Remove the recoil housing fasteners (1).

2.

Separate the housing (2) from the engine. Service the
recoil at this point if needed.

3.

Remove the recoil basket fasteners (3) and remove the
recoil basket from the flywheel.

4.

Remove the flywheel nut (4).

5.

Hold the flywheel (5) with holding tool (PN 8700229).

6.

Place the flywheel puller tool (PN 2871043) onto the
flywheel and remove the flywheel.

7.

Remove the wire keeper darts from the case.

8.

Remove the fasteners from the stator pick ups (7).

9.

Remove the stator fasteners (6) from the stator (8). 

10. Remove the stator from the crankcase.

700/900 RECOIL/STATOR ASSEMBLY

1.

Replace the stator wires through the crankcase.

2.

Replace the plastic wire keeper darts into the case so that
they hold the harness in place.

3.

Replace the stator bolts and torque them to 144 in-lb
(16Nm).

4.

Replace the stator pick up fasteners and torque them to 48
in-lb (5.4Nm).

WARNING

Do not use a hammer to press in the mechanical seal 

or damage to the seal will occur. The mechanical seal 

needs to be pressed in with an arbor press and instal-

lation tool. The installation tool will set the mechanical 

seal at a pre-determined installation height for correct 

operation.

Blue sealant

Case side

Cover side

PW-46986

1

2

3

4

5

6

7

8

6.15

ENGINE

5.

Replace the flywheel onto the crankshaft end and hold the
flywheel with the holding tool (PN 8700229).

6.

Torque the flywheel holding nut to 90 ft-lb(122Nm).

7.

Replace the recoil basket fasteners to 108 in-lb (12Nm).

8.

Replace the recoil housing.

9.

Torque the recoil housing fasteners to 108 in-lb (12Nm).

500/600 HO ENGINE

500/600 HO TORQUE SPECIFICATIONS

1 =Apply Loctite 242 to threads of bolt.

2= Apply Pipe sealant to threads.

3= See torque sequence.

600 HO IQ ENGINE REMOVAL

NOTE:  Inspect all parts for wear or damage during 
disassembly. Replace all seals, o-rings, and gaskets 
with Genuine Pure Polaris parts during assembly. 
Refer to the ‘INSPECTONS” on page 3.5 for general 
inspection procedures.

1.

Remove the side panels.

2.

Disconnect battery ground (-) if applicable.

3.

Turn the fuel valve to the “OFF” position (1).

4.

Remove the exhaust system. See “EXHAUST
REMOVAL” on page 3.16

5.

Disconnect the CDI box and harness from the air box.

6.

Pull up the air box and disconnect the vent lines and coil
connections.

7.

Remove the spark plug caps from the spark plugs.

8.

Remove the air box.

9.

Remove the recoil handle and secure the recoil rope (2).

10. Remove the drive belt, driven clutch and drive clutch.

‘DRIVE CLUTCH REMOVAL” on page 7.10 and
‘DRIVEN CLUTCH REMOVAL” on page 7.20.

Table 6-3: 

ENGINE

500/600/600HO

SPARK PLUG

18 ft-lb (24Nm)

CYLINDER HEAD

22ft-lb (30Nm)1,3

BLEEDER SCREW

70 in-lb (8Nm)

THERMOSTAT HOUSING

9 ft-lb (12Nm)

WATER TEMPERATURE SENSOR

18-40ft-lb

(24-54Nm)2

WATER INLET PIPE

75ft-lb (102Nm)2

DETIONATION SENSOR

168 in-lb(19Nm)

CYLINDER BASE NUTS

32 ft-lb (43Nm)3

EXHAUST VALVE COVER BOLTS

12 ft-lb (16Nm)

EXHAUST VALVE NUT

 144 in-lb (16Nm)1

EXHAUST MANIFOLD BOLTS

22 ft-lb (30Nm)

CARB ADAPTER BOLTS

108 in-lb (12Nm)

OIL PUMP MOUNTING BOLTS

7 ft-lb (9Nm)

CRANCASE PLUGS

10ft-lb (14Nm)2

WATER PUMP IMPELLER NUT

120 in-lb (14Nm)

WATER PUMP COVER BOLTS

108 in-lb (12Nm)

CRANKCASE 6mm

9ft-lb (12Nm)1,3

CRANKCASE 8mm

22ft-lb (30Nm)1,3

CRANKCASE 10mm

N/A

ENGINE STRAP to CHASSIS NUT

18ft-lb (24Nm)

ENGINE STRAP to ENGINE BOLT

45 ft-lb (61Nm)

STATOR BOLTS

60 in-lb(7Nm)1

TRIGGER COIL BOLTS

48 in-lb (5Nm)

FLYWHEEL

90ft-lb (122Nm)1

RECOIL CUP BOLTS

108 in-lb (12Nm)

RECOIL COVER COLTS

108 in-lb (12Nm)

DRIVE CLUTCH BOLT

50 ft-lb(68Nm)

7/16” ENGINE MOUNT STRAP BOLTS

45 ft-lb (61Nm)

REAR MOTOR MOUNTS BRACKET

29 ft-lb

(39Nm)

FRONT MOTOR MOUNT PLATE

N/A

1

2

6.16

ENGINE

11. Remove the cable tie (3) that secures the DET wire to the

exhaust valve vent line.

12. Squeeze the vent line clamps and remove the exhaust

valve vent lines from the top of the exhaust valve base.

13. Disconnect the DET connections (4) that is located above

the carburetors and intake boots.

14. Remove the cable tie holding the water temperature sensor

to the thermostat hose and disconnect the water
temperature sensor (5).

15. Disconnect the throttle position sensor (TPS) from the

carburetor.

16. Disconnect the Regulator Rectifier (6) and the Stator

connections (7). These are located behind the brake disc
area.

17. Loosen up the boot clamps that hold the carburetor onto

the intake.

18. Separate the carburetors from the engine.

19. Disconnect the oil supply lines from the carburetor and

secure the carburetor assembly out of the way.

NOTE:  Plug the carburetor areas with a clean shop 
towel to keep any debris from entering the 
carburetors.

20. Drain the engine coolant.

NOTE:  Disconnect the thermostat hose (5) and 
place the end into a container. Compress air in to 
the system through the thermostat and coolant 
should come out of the hose.

21. Move the thermostat hose clamp up onto the shoulder of

the thermostat fitting (8). Remove the hose and secure it
out of the way.

3

4

5

6

7

8

6.17

ENGINE

22. Move the hose clamp (9) and remove this front radiator

hose from the coolant bottle, and secure it out of the way.

23. Remove the coolant supply hose that is located at the

bottom of the coolant bottle and secure it out of the way.
This will come out with the engine.

24. Remove the rear (10) and left (11) motor mounts located

on the right hand side of the engine. 

25. Remove the left hand rear torque stop fasteners (12)

26. Remove the inside motor mount fastener (13), located

under the PTO carburetor boot.

27. Remove the rear torque stop plate.

28. Remove the front left hand torque stop assembly fasteners

(14) and then remove the torque stop assembly.

29. Remove the LH front motor mount nylock nut (15) and

washer.

9

RH Rear

RH Front

10

11

12

13

14

15