Snowmobile Polaris Two Stroke (2007 year). Manual - part 32

5.21

ENGINE

5

29. Remove and plug the oil supply line going to the oil pump,

and route it through the guide (15).

30. Lift the front of the engine up and then tilt the rear so that

the engine straps clear the motor mount studs.

31. Carefully place the engine on top of the shock tower brace.

32. Remove the oil cable from the oil pump lever by holding

the pump open and rotating the cable and keeper to the slot
(16) in the pump arm.

33. Loosen up the lock nuts (17) and remove the cable from the

engine.

34. Remove the engine from the chassis.

15

16

17

5.22

ENGINE

500/600 (Carbureted) Engine Disassembly

1

2

3

4

5

6

7

8

9

10

11

12

13

15

16

31

14

14

32 ft-lb

22 ft-lb

17

See Torque sequence

(30 N-m)

LOCTITE

® 242

70 in-lb
(7.9 N-m)

9 ft-lb
(12.2 N-m)

18 ft-lb
(24 N-m)

(43 N-m)

Height Installation 
see  page 5.5

500 Liberty Engine Shown

If NEW 

18

19

20

21

23

22

24

25

26

27

29

30

on page 5.22

28

5.23

ENGINE

5

1.

Remove the spark plugs (1)

2.

Remove reed valve assembly. See “Reed Valve
Disassembly” on page 5.3.

3.

Remove the recoil and stator assembly. See “Recoil/Stator
Removal” on page 5.7.

4.

Remove the head bolts (2).

5.

Remove the head cover (10) and the rubber head seals (11).

6.

Remove the head (13) and cylinder o-rings (14).

7.

Remove the VES assembly. See “Exhaust Valve
Disassembly” on page 5.3.

8.

Remove the cylinder nuts (15) and carefully remove the
cylinders (16) with a slight rocking motion.

9.

Remove the c-clips that hold the wrist pin into the piston.

10. Using the piston pin puller PN PU-45255 remove the piston

pins, and the piston (17) from the crankshaft rod.

11. Remove the water/oil pump assembly. See “500/600/700

Water/Oil Pump Cross Shaft Disassembly” on page 5.6.

12. If removing the engine mounting straps (these straps are

mounted to the engine and bulkhead) label the direction and
placement of each engine strap.

13. Remove the cylinder base gaskets (18) and replace them if

damaged.

14. Turn over the crankcase and remove the bottom crankcase

bolts (31).

15. Turn the crankcase assembly back over and remove the top

of the crankcase (20). 

16. Remove the crankshaft assembly (22-29), and refer to the

General chapter for general engine component inspections
and measurement procedures

.

17. If new cases are to be installed make sure that the new

cylinder studs are installed to the correct length. See
“Cylinder Stud Installation” on page 5.5.

500/600 (Carbureted) Torques

When tightening bolts, nuts, or screws, a torque pattern may
need to be followed to ensure uniform equal tension is applied
to all fasteners. Proper torque application prevents fasteners
from loosening or breaking in critical service. It also minimizes
wear and eliminates premature or needless repair costs.
Following uniform torque application sequence patterns
ensures optimum performance from precision machined, close
tolerance assemblies.

The most common units of torque in the English system are ft-
lb (foot pounds) and in-lb (inch pounds). In the Metric system, 
torque is commonly expressed in units of N-m (Newton 
Meter).

1 =Apply Loctite 242 to threads of bolt.

2= Apply Pipe sealant to threads.

3= See torque sequence.

500/600 (Carbureted) Cylinder Head Torque 

Pattern

ENGINE 500/600

SPARK PLUG

18 ft-lb (24 N-m)

CYLINDER HEAD

22ft-lb (30 N-m)1,3

BLEEDER SCREW

70 in-lb (8 N-m)

THERMOSTAT HOUSING

9 ft-lb (12 N-m)

WATER TEMPERATURE SENSOR

18-40ft-lb 

(24-54 N-m)2

WATER INLET PIPE

75ft-lb (102 N-m)2

DETIONATION SENSOR

168 in-lb(19 N-m)

CYLINDER BASE NUTS

32 ft-lb (43 N-m)3

EXHAUST VALVE COVER BOLTS

12 ft-lb (16 N-m)

EXHAUST VALVE NUT

 144 in-lb (16 N-m)1

EXHAUST MANIFOLD BOLTS

22 ft-lb (30 N-m)

CARB ADAPTER BOLTS

108 in-lb (12 N-m)

OIL PUMP MOUNTING BOLTS

7 ft-lb (9 N-m)

CRANCASE PLUGS

10ft-lb (14 N-m)2

WATER PUMP IMPELLER NUT

120 in-lb (14 N-m)

WATER PUMP COVER BOLTS

108 in-lb (12 N-m)

CRANKCASE 6mm

9ft-lb (12 N-m)1,3

CRANKCASE 8mm

22ft-lb (30 N-m)1,3

ENGINE STRAP to CHASSIS NUT

18ft-lb (24 N-m)

ENGINE STRAP to ENGINE BOLT

45 ft-lb (61 N-m)

STATOR BOLTS

60 in-lb(7 N-m)1

TRIGGER COIL BOLTS

48 in-lb (5 N-m)

FLYWHEEL

90ft-lb (122 N-m)1

RECOIL CUP BOLTS

108 in-lb (12 N-m)

RECOIL COVER COLTS

108 in-lb (12 N-m)

DRIVE CLUTCH BOLT

50 ft-lb(68 N-m)

7/16” ENGINE MOUNT STRAP BOLTS

45 ft-lb (61 N-m)

REAR MOTOR MOUNTS BRACKET

29 ft-lb (39 N-m)

1

2

3

4

5

6

7

8

9

10

MAG

PTO

12

11

Head Pattern

22 ft-lb (30 N-m)

5.24

ENGINE

500/600 (Carbureted) Cylinder Base

500/600 (Carbureted) Crankcase Torque 

Pattern

500/600 (Carbureted) Engine Assembly

1.

Assemble the oil/water pump cross shaft as outlined on
See “500/600/700 Water/Oil Pump Cross Shaft
Assembly” on page 5.6.

2.

Set the crankshaft assembly (22-29) into the lower
crankcase (27).

3.

Fill the cross shaft section of the lower crankcase with cross
shaft break in lube PN 2872435.

4.

Place the top crankcase (20) on top of the lower crankcase
and crankshaft assembly. Make sure that seals are lined up
properly to each case section.

5.

Apply Loctite 242 to the threads of the lower crankcase
bolts (31).

6.

Assemble the crankcase bolts into the crankcases. Torque
the bolts to 22 ft.lb. (30 N-m). See “500/600 (Carbureted)
Crankcase Torque Pattern” on page 5.24.

7.

Lubricate the small end bearings (21) and the piston pins
with Polaris 2 stroke oil and install the piston onto the
crankshaft with the piston pin removal/installation tool PN
PN PU-45255. 

8.

Install new c-clips in the piston grooves with the gap facing
straight up (12:00 position) or straight down (6:00
position). Make sure that the c-clip is fully seated in the
piston groove. Use c-clip installation tool PN 2872622A.

9.

Install the piston rings onto the piston with the bevel side
up and the gap facing the piston ring locating pin.

10. Install the base gaskets (18) on the upper crankcase.

11. Lubricate the cylinders and pistons with Polaris 2-stroke oil

and carefully install the cylinder onto the pistons by
squeezing the piston rings onto the locating pins and
rocking the cylinder gently from the intake and exhaust
sides.

12. Install the cylinder base nuts (15) and torque to 32 ft-lb(43.4

N-m) in the Cylinder Base pattern. See “500/600
(Carbureted) Cylinder Base” on page 5.24.

13. Install cylinder o-rings (14).

14. Install head cover o-rings (11) with the head cover (10) on

the head.

15. Apply Loctite 242 on head bolt threads (2) and torque to

22ft-lb (29 N-m).

16. Install VES. See “Exhaust Valve Assembly” on page 5.3.

= T 

Head Bolt Torque 22 ft.lb. (30 N-m)

7

3

5

1

2

6

4

8

Cylinder Base Pattern

32 ft-lb (43 N-m)

MAG

PTO

11

9

7

5

1

3

2

4

6

8

12

10

14

13

Case Pattern

(Bolts 1 - 14) 22ft-lb (30 N-m)

PTO

MAG

15

(Bolt 15) 5 ft-lb (7N-m)

= T 

Cylinder base Nut Torque 32 ft.lb. (43 N-m)

= T 

Head Bolt Torque 22 ft.lb. (29 N-m)