Snowmobile Polaris DEEP SNOW (2005 year). Manual - part 28
ENGINE
5.10
EC 55 ENGINE ASSEMBLY
1. Insert oil pump cross shaft (T), spacer (S), and bushing (R).
2. Install a new o--ring (H) on the oil pump.
3. Place oil pump aside for later installation.
4. Set the crankshaft into the lower case half.
NOTE:
Make sure that the crankshaft rotates smoothly and does not bind. Rotate the bearings so that the anti--
rotation pins are testing in their appropriate galleries.
5. Apply 3--Bondt (PN 2871557) sealer to the top half of the crankcase.
6. Apply Polaris 2--stroke engine oil to the oil pump cross shaft in the lower half of the crankcase.
7. Install new crankcase oil seals (P).
8. Match the top half of the crankcase to the lower and hold the case halfs together and turn upside down.
9. Install the crankcase bolts (O) to 17--18 ft.lbs (22--25Nm) in the pattern on page 5.2.
10. Turn the case over and install the pistons with the arrow on the piston crown facing the flywheel (MAG) side. This will
orentate the piston so that the piston ring locating pins will be on the intake side of the engine.
11. Apply Polaris 2--stroke engine oil to the wrist pin and small end bearings and install them onto the crankshaft with the piston
installation tool (PN 2830386).
12. Lubricate rings and piston with Polaris 2--stroke engine oil and install rings with the letter, mark or beveled side facing
upward.
13. Install the c--clips into the piston so that the opening of the “C” is positioned straight up or down.
14. Install the reed valves (N) in the crankcase, and then install new base gaskets.
15. Carefully compress the rings and install each cylinder onto the crankcase.
16. Torque the cylinder base nuts (M) to 24--28 ft.lbs. (33--39Nm) in the pattern on page 5.2.
17. Install a new head gasket with the “EX” on the exhaust side and the “UP” on the intake side of the engine.
18. Insert the head bolts (J) and torque to 18--19 ft.lbs. (25--27Nm) in the pattern on page 5.2.
19. Insert the locating dowels on the stator housing that match up with the crankcase, route the stator wire harness.
20. Install the flywheel, lockwasher, Woodruff key, and flywheel nut onto the shaft. With the flywheel holding wrench hold the
flywheel and torque the flywheel nut to 60--65 ft.lbs. (83--90Nm).
21. Install the recoil basket (F).
22. Install the recoil cover (E) onto the stator housing.
23. Install the CDI box on the flywheel cover.
24. Insert the vibration dampener (D) into the cooling fins between the cylinders on the intake side of the engine.
25. Install the two fan shrouds (C) making sure that they interlock before tightening down.
26. Install the oil pump onto the lower case half. Apply blue Loctite 243 to the oil pump mounting screw threads and torque to
48--72 in. lbs. (5.5--8.3Nm). Make sure you install all oil pump shims (I) in the same order as removal.
27. Install intake boots (B), carburetor clamps (C) and carburetors.
28. Route each oil line on the oil pump to the correct position.
29. Install engine into chassis, bleed the oil pump and premix the first tank of gas at a ratio of 32:1 see page 4.6 for pre--mix
instructions.