Polaris 2007 Two Stroke - Reed Valve Assembly; Thermostat Replacement

5.4
ENGINE
5. Separate the intake boot(s) (4) from the reed cage (6)
6. If reed stuffers are used separate the reed stuffer(s) (5) from
the reed cage (6) and inspect the reeds (7) before they are
removed from the reed cage.
NOTE: Measure the air gap between the fiber reed and
the reed block. The air gap should not exceed .015"
(.38mm). If clearance is excessive DO NOT attempt to
reverse the reeds to reduce the air gap. Always replace
them if damaged or worn. Check each fiber reed for white
stress marks or missing material.
7. If damaged remove and replace the reeds (7) on the reed
cage (6).
Reed Valve Assembly
1. If reeds (7) were replaced or removed, assemble the reeds
to the reed cage (6).
2. Place the assembled reed cage (6-7) into the engine case.
3. Insert the reed stuffers (5) into the reed cage.
4. Place the intake boot(s) (4) onto the installed reed cage.
NOTE: 600/700 CFI engines must have the boots
placed onto the case in the correct orientation. The
boot has a “P” for PTO side and “M” for MAG.
5. If applicable replace the hose guide(s) (3) in the appropriate
places.
6. Insert the intake boot fasteners (2) and torque to 9 ft-lb (12
N-m).
7. Install the carburetors or throttle body and torque the hose
clamps (1) to 11 in-lb (1 N-m).
Thermostat Replacement
1. Remove the thermostat cover, by removing the cover bolts
(3).
2. Check the o-ring (6) condition and replace it if it is
damaged.
3. Replace the thermostat (5). Make sure that the spring side
is facing downward or toward the engine.
4. Replace cover (4) onto the thermostat.
5. Torque the cover fasteners (3) to 9 ft-lb (12 N-m).
6. Make sure that the bleed screw (1) and washer (2) is
installed.
The air gap should not exceed .015” (.30mm)
PTO SIDE
MAG SIDE
= T
Intake Boot Fasteners: 9 ft-lb (12 N-m)
= T
Carburetor/Throttle Body Fasteners: 11 in-lb (1N-m)
= T
Cover Fasteners: 9 ft-lb (12 N-m)
600
1
2
3
4
5
6
9 ft-lb
(12 N-m)