Snowmobile Polaris EDGE / WIDETRAK (2007-2012 year). Manual - part 28

5.10

Engine Systems

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

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
added or subtracted from the assembly.

Install oil pump drive gear into crankcase. Install
bushing into bore. Verify the bushing is fully seated.

Measure from the oil pump mounting surface to the
top of the bushing. Record measurement as
MEASUREMENT A.

• MEASUREMENT A =

_________________________

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 gasket is
installed on the oil pump before taking measurement.

• MEASUREMENT B =

_________________________

Subtract measurement B from A to determine the total
bushing end play.

Measure the total thickness of the original shims.
Subtract this number from the number obtained in
step 4.

Add or subtract shims to obtain the specified oil pump
bushing end play.

= In. / mm.

Oil Pump Oil Pump Bushing End Play

.008" - .016" (.203 - .406mm)

Available Shims
30803671 - .006" (.15mm)
30803672 - .012" (.30mm)
30803673 - .024" (.60mm)

5.11

Engine Systems

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

EXHAUST VALVE MAINTENANCE

Exhaust Valve Assembly

Exhaust Valve Disassembly

Remove the two horizontal cover fasteners securing
the valve assembly to the cylinder.

Remove exhaust valve assembly from cylinder.

Remove the gasket and discard. Remove the two
vertical cover screws to access the spring and
bellows.

Secure the guillotine, then apply heat to remove the
bellows cap nut.

Separate the cap nut, bellows and bellows washer
from the guillotine.

Remove the guillotine from the base.

Exhaust Valve Assembly

Clean the threads of the guillotine with Primer N.

Insert the base into the clean guillotine.

Apply Loctite 2760 to the first 3 threads on the
guillotine.

Place the bellows washer, bellows and cap nut onto
the guillotine.

Torque the cap nut to specification.

Lubricate the guillotine blade and shaft with engine oil.

Actuate the guillotine to ensure full and free motion.

Install the spring, and cover.

Torque the vertical cover fasteners to specification.

10. Install a new 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.

Optional Exhaust Valve Springs

CAUTION

EV spring under tension. Use care when removing
housing from assembly base.

GUILLOTINE

GASKET

EV BASE w/FITTING

BELLOWS WASHER

BELLOWS

CAP NUT

SPRING

COVER

VERTICAL SCREWS

HORIZONTAL SCREWS

= T

Guillotine Cap Nut Torque: 16 Ft.Lbs. (22 Nm)

= T

Cover/Base Fastener Torque: 12 Ft.Lbs. (16 Nm)

SPRING

COLOR

LOAD

@ 1

INCH

(

LBS

LOAD

@ .630

INCHES

(

LBS

7041704-01

Blue

4.0

6.0

7041704-02

Orange

5.5

8.3

7041704-03

Pink

4.7

7.1

7041704-04

Purple

3.1

4.7

7041704-05

Yellow

2.4

3.6

7041704-06

White

1.6

2.8

5.12

Engine Systems

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

RECOIL PULLEY

Rope Removal and Installation

With the recoil housing removed from the engine, un-
tie any knots (handle) in the recoil rope and allow the
pulley to slowly unwind.

Remove the nut, friction plate, friction spring, ratchet
and ratchet spring from the pulley.

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 the
pulley is removed.

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.

If the pulley recoil spring was removed during
disassembly, install the spring by spiraling the spring
counterclockwise toward the center of the housing.

Lubricate the center shaft and spring with Premium
grease.

Wind the rope counterclockwise around the pulley as
viewed from the ratchet-side of the pulley.

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.

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 hooked 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.

NUT

FRICTION PLATE

FRICTION SPRING

RATCHET

RATCHET SPRING

ROPE

RECOIL PULLEY

RECOIL SPRING

TAB (ENGAGES INSIDE HOUSING)

TAB (ENGAGES INSIDE PULLEY)

ROPE GUIDE (HOLE)

488 SHOWN - ALL MODELS SIMILAR

CAUTION

Recoil spring under high tension. Always wear eye

protection when working with recoil housing

components.

5.13

Engine Systems

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

ENGINE MOUNTS

340 Engine Mounting

Fastener

Torque

Note

Engine Plate Mounting Nuts

28 ft.lbs. (38 Nm)

Engine Plate Left-Front Mounting Bolt 28 ft.lbs. (38 Nm)

Engine Plate-to-Engine Bolts

45 ft.lbs. (61 Nm)

Vibration dampeners must be installed
perpendicular to plate and centered in
bushings and caps.

Exhaust Manifold Nuts

15 ft.lbs. (20 Nm)

EXHAUST MANIFOLD

ENGINE PLATE

ENGINE STRAP

SPACER

VIBRATION DAMPENERS

DAMPENER CAPS

BUSHINGS

VIBRATION DAMPENERS

DAMPENER CAPS

Content .. 26 27 28 29 ..