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Snowmobile Polaris EDGE / WIDETRAK (2007-2012 year). Manual - part 34

5.34

Engine Systems

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

Magneto Assembly

Disassembly / Assembly Process

Remove the recoil/waterpump housing from the
engine. Remove hub and belt pulley.

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

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
coils 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 / IGNITION COIL PACK

FLYWHEEL

EXCITER COIL

LIGHTING COIL

STATOR PLATE

Fastener

Torque

Note

Flywheel Nut

61 - 70 ft.lbs.
(83 - 95 Nm)

Flywheel and
crankshaft tapers
to be clean and
dry.

Exciter / Lighting
Coil
Magneto Plate

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

5.35

Engine Systems

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

Crankcase Assembly

Disassembly / Assembly Process

Remove the recoil/waterpump housing assembly, oil
pump, flywheel, coils, and cylinder 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.

CRANKCASE SEAL

IMPULSE HOSE FITTING

CRANKCASE SEAL

UPPER CRANKCASE

LOWER CRANKCASE

CRANKCASE DRAIN SCREW

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.

5.36

Engine Systems

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

Piston and Crankshaft Assembly

Disassembly / Assembly Process

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

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

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

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

Install the piston rings with the beveled edge facing

upwards.

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

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

THRUST WASHER

NEEDLE BEARING

CONNECTING ROD

PISTON PIN

BEARING

SPACER

RETAINING RING

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

61 - 70 ft.lbs.
(83 - 95 Nm)

Flywheel and
crankshaft tapers
to be clean and
dry.

5.37

Engine Systems

9923396 - 2007-2012 EDGE/Widetrak LX Service Manual

500EV LIQUID-COOLED ENGINE

500EV Cylinders / Cylinder Head

Disassembly / Assembly Process

Remove the coolant from the engine using a siphon,
wet/dry vac, or drain pan.

Remove the air box, exhaust pipe and resonator from

the engine compartment.

Remove the high tension wires and spark plugs from
the cylinder head.

Remove the thermostat housing outlet cooling hose
from the housing.

Loosen all, then remove all head cover fasteners.
Clean the fastener threads to remove any thread
locking residue.

Discard the head cover and cylinder head o-rings.
Always use new o-rings during assembly.

Inspect the cylinder head / combustion domes for any
damage. Measure cylinder head flatness. Replace
cylinder head if required.

Loosen all, then remove the cylinder bolts. Clean the
bolt threads to remove any thread locking residue.

Carefully pull each cylinder upwards taking care not
to drop the piston and rod abruptly against the
crankcase.

10. Remove the cylinder base gaskets. Use a gasket

scraper to clean the gasket residue from the
crankcase and cylinder bases.

11. Inspect the cylinder walls. Nicasil cylinders can only

be lightly honed. Damage that cannot be removed
with a light hone requires cylinder replacement or re-
lining.

12. The assembly process is the reverse of disassembly.
13. Always use new gaskets and o-rings during

assembly. Liberally coat the inside of each cylinder
and the outside of each piston with Polaris two-stroke
engine oil.

14. When installing a piston into a cylinder, verify each

piston ring opening is located at each piston ring
locating pin. Squeeze the top ring, then carefully slide
the cylinder over the compressed ring. Do the same
with the bottom ring.

15. Follow the torque specifications and torque

sequences located at beginning of chapter when
tightening fasteners.

= T

A = 70 In.Lbs. (8 Nm)
B = 9 Ft.Lbs. (12 Nm) - Apply Loctite 242
C = 25 Ft.Lbs. (34 Nm) - Apply Loctite 242
D = 37 Ft.Lbs. (50 Nm)

HEAD COVER

O-RINGS

CYLINDER HEAD

O-RINGS

CYLINDERS

THERMOSTAT

THERMO SENSOR

Content .. 32 33 34 35 ..