Snowmobile Polaris EDGE / WIDETRAK (2007-2012 year). Manual - part 32

5.26

Engine Systems

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

©2011 Polaris Sales Inc.

Oil Pump Assembly - Fleet Models

Disassembly / Assembly Process

1.

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

2.

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

3.

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

4.

Remove drive gear using a needle nose pliers.

5.

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

6.

Install the exact amount of shim(s) that were removed.

Verify return spring works and applies tension to the
lever.

7.

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

GASKET

AIR BLEED HOSE

BUSHING

O RING

SHIM WASHERS (AS REQUIRED QTY.)

OIL PUMP DRIVE GEAR

WASHER

LEVER

RETURN SPRING

CHECK VALVE

NOZZLE

GROMMET

(ARROW TO OIL TANK)

OIL TANK

Fastener

Torque

Note

Oil Pump Screws

48 - 72 in.lbs.
(5.5 - 8.3 Nm)

Oil pump is not 
serviceable.

5.27

Engine Systems

5

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

©2011 Polaris Sales Inc.

Magneto Assembly

Disassembly / Assembly Process

1.

Remove the blower / recoil housing from the engine.

2.

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.

3.

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.

4.

Thoroughly clean the crankshaft nose and flywheel

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

5.

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

6.

Assembly is the reverse of disassembly.

IGNITION COIL PACK

FLYWHEEL / FAN ASSEMBLY

TRIGGER COIL

MAGNETO (STATOR)

SPARK PLUG CAPS

CDI MODULE

Fastener

Torque

Note

Flywheel Nut

58 - 72 ft.lbs.
(78.5 - 98 Nm)

Flywheel and 
crankshaft tapers 
to be clean and 
dry.

Magneto
Magneto Plate

5 - 6.5 ft.lbs.
(7 - 9 Nm)

5.28

Engine Systems

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

©2011 Polaris Sales Inc.

Crankcase Assembly

Disassembly / Assembly Process

1.

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

2.

Remove engine mount plate fasteners from the lower
crankcase.

3.

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

4.

Discard both crankshaft seals.

5.

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

6.

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

7.

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

8.

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.

9.

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

CRANKCASE SEAL

CRANKCASE SEAL

LOWER CRANKCASE

CRANKCASE DRAIN SCREW

IMPULSE HOSE FITTING

Fastener

Torque

Note

Crankcase

15 - 18 ft.lbs.
(20 - 25 Nm)

Apply Three Bond 
1215 to 
crankcase mating 
surfaces.

5.29

Engine Systems

5

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

©2011 Polaris Sales Inc.

Piston and Crankshaft Assembly

Disassembly / Assembly Process

1.

Using a small, flat-blade screwdriver, remove the c-
clips. Discard the c-clips.

2.

Remove the piston pins using the piston pin puller, PN
2870386.

3.

When replacing a piston, always replace the rings, c-
clips, pins and needle bearings with new parts.

4.

Inspect the crankshaft as outlined in the Engine
Inspection section within this chapter.

5.

Install the piston rings with the beveled edge facing

upwards.

6.

The piston ring locator pins and ring open-ends
always face the intake-side of the engine.

7.

Always lubricate the piston assembly and cylinder
with two-stroke engine oil when installing the cylinder
over the piston.

PISTON RINGS

PISTON

C CLIP

PISTON PIN

NEEDLE BEARING

NEEDLE BEARING

CONNECTING ROD PIN

THRUST WASHER

THRUST WASHER

THRUST WASHER

BEARING

SPACER

BEARING

PTO CRANKWEB

CTR CRANKWEB

MAG CRANKWEB

BEARING

WASHER

FLYWHEEL NUT

FLYWHEEL KEY

CAUTION

Wear eye protection when removing or installing piston
c-clips.

Fastener

Torque

Note

Flywheel Nut

58 - 72 ft.lbs.
(78.5 - 98 Nm)

Flywheel and 
crankshaft tapers 
to be clean and 
dry.