Snowmobile Polaris IQ (2007-2008 year). Manual - part 35

5.18

Engine and Cooling Systems

600 HO Carbureted Recoil / Magneto

Disassembly / Assembly Process

Remove the exhaust pipe and resonator.

If the recoil assembly does not require attention, the recoil
rope can remained attached to the handle. If recoil
component work is desired, reference the Recoil Assembly
section. See “Recoil Assembly” on page 5.11.

Remove the recoil / magneto housing cover. The recoil
assembly is located inside the housing.

Remover the recoil hub from the flywheel. Secure the
flywheel with a strap wrench, PN PU-45419. Remove the
flywheel nut and washer.

Using the flywheel puller tool, PN 2871043, insert the
puller’s three screws into the flywheel.

NOTE: Do not thread the puller screws into the
magneto/stator located behind the flywheel.

Turn the puller center bolt in until the flywheel “pops” off
of the crankshaft.

Mark the location of the magneto / stator plate in several
places using a scribe.

Remove the magneto / stator from the crankcase.

Clean the crankshaft and flywheel tapers with a solvent
such as clutch cleaner.

10. Assembly is reverse of disassembly. Reference the fastener

torque specifications at the beginning of the chapter.

11. Do not use an impact wrench to install the flywheel nut.

RECOIL HANDLE

ROPE GUIDE

RECOIL HOUSING

SPRING

ROPE REEL

RETURN SPRING

RATCHET

FRICTION SPRING

FRICTION PLATE

RECOIL HUB

FLYWHEEL NUT

FLYWHEEL

MAGNETO / STATOR

= T

A = 9 Ft.Lbs. (12 Nm)
B = 5 Ft.Lbs. (7 Nm) - Apply Loctite 242 (Stator)
C = 90 Ft.Lbs. (122 Nm) - Apply Loctite 242

5.19

Engine and Cooling Systems

600 HO Carbureted Pistons / Crankshaft

Disassembly / Assembly Process

To remove the pistons, follow the process for removing the
cylinder head and cylinders from the engine.

To remove the crankshaft, follow the process for
disassembling the crankcase assembly.

With the piston out of the cylinder, remove one of the c-
clips and discard. Never re-use piston c-clips.

Push the piston pin out of the piston and upper rod bearings.
Inspect the pin for galling and abnormal wear. Inspect the
needle bearing by feel and replace as required.

New pistons are supplied with new rings and a piston pin.
It is recommended that new needle bearings be installed as
well.

When installing a new piston, insert one c-clip into the
piston making sure the open end is 180° opposite of the
groove opening.

Apply a liberal amount of Polaris two-stroke engine oil to
the needle bearings, piston pin and piston assembly.

Push the pin in to the piston, then through the needle
bearing. Install the remaining c-clip with the open end is
180° opposite of the groove opening.

NOTE: Always use new cylinder base gaskets.

Apply a liberal amount of Polaris two-stroke oil to the
cylinder wall. Align the piston ring gaps around the piston
locating pins. Compress the upper ring, then carefully slide
the cylinder down over the ring.

10. Compress the lower ring, then slide the cylinder down over

the ring.

PISTON

PISTON PIN

PISTON RINGS

C-CLIP

NEEDLE BEARINGS

PTO CRANKCASE SEAL

BEARINGS

BEARING

FLYWHEEL KEY

MAG CRANKCASE SEAL

Piston Matrix

Engine Model

Piston PN

Piston ID

S3273-6044-PF6F

2202258

(Subs to 2203319)

EK-2202b

S3274-6044-PF6F

S3466-6044-PU6F

2203319

EK-2202c

S3467-6044-PU6F

5.20

Engine and Cooling Systems

600 HO Carbureted Crankcase

Disassembly / Assembly Process

Remove the engine from the engine compartment.

Follow the process for removing the cylinder head,

cylinders, pistons, flywheel / recoil housing, and the water
/ oil pump.

Remove the intake boots, and reed assemblies. Discard any
seals or gaskets.

Remove the crankcase fasteners then carefully pry apart the
crankcase halves. Discard the PTO and MAG crankshaft
seals.

Clean the two crankcase mating surfaces with carburetor
cleaner and a gasket remover. Flush out the crankcase.

Reinstall the crankshaft back into the lower crankcase using
two new crankcase seals.

Apply a thin bead of Three Bond 1215 to the lower
crankcase mating surface. Install the upper crankcase.

Loosely install the crankcase fasteners, then torque to the
specifications at the beginning of the chapter. Use the
correct torque sequence when tightening the screws.

INTAKE BOOTS

REED STUFFERS

REED ASSEMBLIES

IMPULSE FITTING

OIL INJECTION CHECK VALVES

CRANKCASE

WATERPUMP BUSHING SCREW

DRAIN PLUGS

CYLINDER STUDS

B,C

= T

A = 9 Ft.Lbs. (12 Nm)
B = (M8) - 22 Ft.Lbs. (30 Nm) - Apply Loctite 242
C = (M6) - 9 Ft.Lbs. (12 Nm) - Apply Loctite 242

= In. / mm.

Long Studs Height (Exhaust side) = 3.66

(93mm)

Small Stud Height (Intake side) = 2.16

(55mm)

5.21

Engine and Cooling Systems

600 HO Carbureted Water / Oil Pump

Disassembly / Assembly Process

IMPORTANT: Use the mechanical seal installation

tool to install the water pump seal, PN: 2872010.

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

Remove the airbox, exhaust pipe and resonator. Remove
the hose connected to the water pump cover.

To access the impeller and mechanical seal, remove the
water pump cover. Discard the water pump cover gasket.

Remove the impeller nut, impeller and washers from the
cross shaft.

Carefully pry the mechanical seal and seal out of the
crankcase.

Water pump assembly is the reverse of disassembly.

Always use new seals and gaskets during assembly.

To remove the oil pump / cover, remove the two fasteners
then pull the pump / cover out of the crankcase bore.
Discard the gasket.

The cross shaft can be extracted from the water pump side
of the crankcase.

Assembly is the reverse of disassembly. Always use new
o-rings, seals and gaskets during assembly.

10. Install a new seal onto the shaft from the water pump side.

11. To install a new water pump seal, use the seal installation

tool, PN 2872010. Verify the seal lips are facing the cross
shaft gear.

OIL PUMP

GASKET

BUSHING

O-RING

WASHER

CROSS SHAFT

WATER PUMP COVER

WATER PUMP COVER GASKET

NUT

WASHER

MECHANICAL SEAL

SEAL

WASHER

= T

A = 7 Ft.Lbs. (9.5 Nm)
B = 10 Ft.Lbs. (13 Nm)
C = 9 Ft.Lbs. (12 Nm)

Content .. 33 34 35 36 ..