Snowmobile Polaris IQ (2007-2008 year). Manual - part 40

5.38

Engine and Cooling Systems

21.  Place the engine mount washers and fasteners (8) onto the

engine mount studs. Torque to specification.

22. Install the right hand chassis brace.

23. Apply Blue Loctite™ to the rear fasteners, install all the

rear torque stop fasteners and torque to specification.

24. Adjust the rear torque stop so that you have a clearance of

.010”-.030” (.25-.75mm) from the face of the torque stop
to the surface of the engine. 

NOTE:  If a new torque stop is installed, install it so
that the nub is touching the engine. This nub is .030"
(.75mm) long.

25. Adjust the engine isolator limiter (if equipped) so the stop

is bottomed out on the brace. 

= T 

Engine Mount Fasteners: 28 ft.lb (37.9 N-m)

= T 

Rear Torque Stop Fasteners: 28 ft.lb (37.9 N-m)

= In. / mm. 

Rear Torque Stop Clearance:

.010"-.030" (.25-.75mm)

Stop touching base

5.39

Engine and Cooling Systems

5

26. Install the front torque stop assembly and torque the plate

fasteners to specification.

27. Install the air box onto the carburetor rack. Make sure to line

up the air box tabs with the air box plate.

28. Install the drive clutch. See “Drive Clutch Installation” on

page 6.20.

29. Install the driven clutch. See “Driven Clutch Installation”

on page 6.21.

30. Install the drive belt. 

31. On FI models, connect he fuel filter and fuel return line by

pushing them together until you hear a audible “click”.

32. Secure the fuel return line “P” clamp onto the side of the

airbox.

33. Place the fuel filter back into the airbox-mounted holder.

34. Connect the ECU connection into the ECU.

35. Connect the EV solenoid connection to the EV solenoid.

36. Connect the coil connections to the coils. 

NOTE:   The WHITE connector goes to the MAG coil
(upper). The BLUE connector goes to the PTO coil
(lower).

37. Connect the regulator rectifier connections.

38. Connect intake air sensor to the air box.

= T 

Front Torque Stop Fasteners: 28 ft.lb (37.9 N-m)

5.40

Engine and Cooling Systems

39. Connect the EV solenoid vent lines back onto the EV bases

and install the panduit strap around the spark plug wires as
shown.

40. Install the electrical center/belt holder over the electrical

center by aligning the rear buttons to the rear of the clutch
cover and installing the two fasteners.

41. Install the Nylock nuts and two T40 Torx bolts to the front

and the two T40 to the rear of the LH and RH chassis brace
and install the braces.

NOTE: Install the long bolts and the spacer on the
front portion of the bar before inserting it into the
mounting area.

42. Replace the nosepan plugs were removed to access the front

chassis brace fasteners.

43. Route the recoil rope through the eyelet on the chassis brace

and secure handle once past the console.

44. Install the exhaust system. 

45. Add coolant and bleed system. See “Cooling System

Bleeding” on page 3.6.

46. Premix the first tank of fuel. See “2 Stroke Gasoline / Oil

Pre Mix” on page 2.7.

47. Test run the unit and clear any codes with Digital Wrench.

48. After test running check drive and driven clutch torque.

5.41

Engine and Cooling Systems

5

COOLING SYSTEMS

Thermostat Replacement

1.

Remove the housing cover, by removing the cover bolts.

2.

Check the gasket condition and replace if damaged.

3.

Replace the thermostat. Make sure that the spring side is
facing downward or toward the engine.

4.

Replace cover. Torque the cover fasteners to specification.

5.

Verify the bleed screw and washer are installed.

Thermostat Orientation

The thermostat must be installed in the cylinder head has
shown in the illustrations.

Center Thermostat Location

Offset Thermostat Location

800 CFI Thermostats

There are two different thermostats used depending on
the engine model number. 

The larger bleed hole thermostat is designed for cooling
systems that do not feature a bypass circuit in the cooling
system.

CAUTION

Allow engine to cool completely before working with the 

engine cooling system.

Engine coolant can be under pressure and hot. Escap-

ing steam and/or coolant may cause severe burns to ex-

posed skin.

= T 

Cover Fasteners: 9 Ft.Lbs. (12 Nm)

BLEED SCREW

WASHER

HOUSING COVER

THERMOSTAT

GASKET

Engine Model

Thermostat PN Bleed Hole ID

S3489-8044-PU8E

7052433

2 mm

S3471-8044-PU8E

7052452

3.5 mm

BRIDGE ALIGNED WITH HOLES