Snowmobile Polaris EDGE / WIDETRAK (2007-2012 year). Manual - part 30

5.18

Engine Systems

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

Cylinder Assembly

Disassembly / Assembly Process

Remove the carburetors, intake boots, exhaust
manifold, and blower housing from the engine
assembly. Discard all used gaskets.

Remove cylinder head nuts. Remove cylinder head,
then discard gasket.

Remove the cylinder base nuts. Lift the cylinder off of
the crankcase. Discard the cylinder base gasket.

When re-installing a cylinder, coat the piston and
cylinder walls with Polaris Two-Stroke engine oil.

Verify the piston rings are centered around each
piston ring locating pin before inserting the piston into
the cylinder.

Install cylinder base gaskets with adhesive strip facing
upwards, if applicable.

Install head gasket with seal ring facing down,

towards cylinder.

Assembly is the reverse of disassembly.

CYLINDER HEAD

HEAD GASKET

CYLINDER

CYLINDER BASE GASKET

INTAKE BOOT

SCREW CLAMP

EXHAUST GASKETS

OIL INJECTOR

Fastener

Torque

Note

Spark Plug

18 ft.lbs. (24 Nm)

Apply anti-seize to
threads.

Cylinder Head

20 ft.lbs. (28 Nm)

Cylinder Base Nuts 18 ft.lbs. (24 Nm)

Intake Boots

5 ft.lbs. (7 Nm)

5.19

Engine Systems

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

Oil Pump Assembly

Disassembly / Assembly Process

Remove the two pump mounting screws. Pull pump
out of crankcase bore. Discard o ring.

Extract shim(s) behind pump body. Count the number
of shims and retain.

Extract bushing and inspect. Replace if abnormal
wear and tear is found.

Remove drive gear using a needle nose pliers.

Lubricate all parts with Polaris Two-Stroke engine oil
during re-assembly.

Install the exact amount of shim(s) that were removed.
Verify return spring works and applies tension to the
lever.

Follow the oil pump bleed procedure outlined in the
Maintenance chapter.

OIL PUMP DRIVE GEAR

WASHER

O RING

SHIM WASHERS (AS REQUIRED QTY.)

LEVER

RETURN SPRING

AIR BLEED SCREW

BUSHING

Fastener

Torque

Note

Oil Pump Screws

48 - 72 in.lbs.
(5.5 - 8.3 Nm)

Oil pump is not
serviceable.

5.20

Engine Systems

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

Magneto Assembly

Disassembly / Assembly Process

Remove the blower / recoil housing from the engine.

To remove the flywheel nut and washer, secure the
flywheel using the flywheel holding wrench, PN
8700229.

NOTE: Do not secure the flywheel with a strap wrench
around the fan blades as blade damage may occur.

Remove the flywheel from the crankshaft using the
heavy duty flywheel puller, PN 2871043-A.

NOTE: Do not thread the flywheel puller bolts into the
magneto (stator) located behind the flywheel.

Thoroughly clean the crankshaft nose and flywheel

nut threads. Inspect the flywheel key for damage.
Replace if damage is found.

Scribe a line in the magneto plate and crankcase to
ensure alignment when re-assembled.

Assembly is the reverse of disassembly.

CDI MODULE

IGNITION COIL PACK

MAGNETO (STATOR)

FLYWHEEL / FAN (1 PIECE)

MAGNETO (STATOR) PLATE

TRIGGER COIL

Fastener

Torque

Note

Flywheel Nut

62 - 70 ft.lbs.
(83 - 95 Nm)

Flywheel and
crankshaft tapers
to be clean and
dry.

Magneto
Magneto Plate

5 - 6.5 ft.lbs.
(7 - 9 Nm)

5.21

Engine Systems

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

Crankcase Assembly

Disassembly / Assembly Process

Remove the blower housing assembly, oil pump,
flywheel and magneto, and cylinders from the
crankcase assembly. Discard all gaskets and o rings.

Remove engine mount plate fasteners from the lower
crankcase.

Remove the crankcase fasteners. Thoroughly clean
the fasteners to remove any locking agents.

Discard both crankshaft seals.

Thoroughly clean the two crankcase mating surfaces
and the inner crankcases. Inspect for cracks. Verify
both crankcase drain screws are securely installed.

Apply a thin bead of Three Bond 1215 to both
crankcase mating surfaces.

Lubricate the oil pump drive gear with two-stroke
engine oil and install into crankcase.

Install crankshaft and two new crankcase seals. Verify
seal lips face the inside of the engine. Ensure
crankshaft retaining ring and bearing locating pins are
seated correctly before installing upper crankcase.

Torque crankcase fasteners to specified torque and
sequence outlined at beginning of chapter.

UPPER CRANKCASE

IMPULSE HOSE FITTING

CYLINDER STUDS

ALIGNMENT DOWEL

CRANKSHAFT SEAL

LOWER CRANKCASE

Fastener

Torque

Note

Crankcase

8mm
16 - 18 ft.lbs.
(23 - 25 Nm)
10mm
23 - 26 ft.lbs.
(32 - 35 Nm)

Apply Three Bond
1215 to
crankcase mating
surfaces.

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