Snowmobile Polaris EDGE / WIDETRAK (2007-2012 year). Manual - part 33

5.30

Engine Systems

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

©2011 Polaris Sales Inc.

488 LIQUID-COOLED ENGINE

Recoil / Water Pump Housing Assembly

Disassembly / Assembly Process

1.

Clamp recoil rope with a pliers at the engine. Remove
recoil handle from rope, pull the rope through the
console, then tie a knot just above the pliers. Remove
the pliers.

2.

Remove fasteners securing recoil / waterpump
housing to engine. The recoil pulley mechanism is
located inside the housing.

3.

Reference RECOIL PULLEY section for recoil
disassembly / assembly information.

4.

Lock the ratchet hub with a large screwdriver and
remove the fasteners that secure the hub and
waterpump pulley to the flywheel.

RATCHET HUB

FRICTION PLATE

FRICTION SPRING

RATCHET

RATCHET SPRING

RECOIL PULLEY

RECOIL SPRING

RECOIL / WATERPUMP HOUSING

ROPE GUIDE

Fastener

Torque

Note

Recoil Hub

9 ft.lbs. (12 Nm)

Friction Plate / 
Recoil Pulley

5 ft.lbs. (7 Nm)

5.31

Engine Systems

5

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

©2011 Polaris Sales Inc.

Water Pump Assembly

Disassembly / Assembly Process

1.

Waterpump impeller, seals, and shaft are not
serviceable.

2.

O ring, belt, cover castings, cover gasket and belt
pulley can be replaced with service parts.

3.

Set belt tension to 1/8" to 3/16" at the midpoint of the
belt.

BELT

BELT PULLEY

WATER PUMP ASSEMBLY

O RING

5.32

Engine Systems

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

©2011 Polaris Sales Inc.

Cylinder Assembly

Disassembly / Assembly Process

1.

Using an siphon pump, remove enough engine
coolant from the fill tube to lower the coolant level
below the cylinder block.

2.

Remove the cylinder head. Discard the head gasket.

3.

Remove the exhaust system, carburetors, and water
pump assembly. Discard all o rings and gaskets.

4.

Remove the nuts securing the cylinder block to the
crankcase. Remove the block, then discard the base
gasket.

5.

Carefully inspect the cylinder block and crankcase for
warping.

6.

When installing a new cylinder base gasket, install
with sealing surface up.

7.

Apply a liberal amount of two-stoke engine oil to each
piston assembly and each cylinder bore. Carefully
install each piston while making sure each piston ring
is centered at each piston ring locating pin.

8.

When installing a new head gasket, install with “UP”
located on the intake-side of engine and readable
when looking down at the engine.

9.

Use new exhaust gaskets and intake o rings when
installing components.

10. When refilling cooling system, follow procedures

outlined in Maintenance chapter.

CYLINDER HEAD

EXHAUST GASKET

CYLINDER BLOCK

CYLINDER BASE GASKET

OIL INJECTOR FITTING

SCREW CLAMP

COOLANT OUTLET PIPE

INTAKE BOOT

THERMO SWITCH

CYLINDER HEAD GASKET

O RING

Fastener

Torque

Note

Cylinder Base 
Nuts

27 - 32 ft.lbs.(37 - 43 
Nm)

Cylinder Head

18 - 20 ft.lbs. (25 -27 
Nm)

Thermoswitch

Apply pipe sealant 
to threads.

5.33

Engine Systems

5

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

©2011 Polaris Sales Inc.

Oil Pump Assembly

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 the oil pump 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.

OIL PUMP DRIVE GEAR

WASHER

BUSHING

SHIM WASHERS (AS REQUIRED QTY.)

LEVER

RETURN SPRING

AIR BLEED SCREW

Fastener

Torque

Note

Oil Pump Screws

48 - 72 in.lbs.
(5.5 - 8.3 Nm)

Oil pump is not 
serviceable.