5.16
ENGINE
500 FUJI ENGINE
For engine removal See “340/550 Fuji/500 Liberty Engine
Removal/installation” on page 5.11.
Disassembly
NOTE: Inspect all parts for wear or damage during
disassembly. Replace all seals, O-rings, and gaskets
with Genuine Polaris parts during assembly. Refer to
General Section for Inspection Procedures.
1. Remove carburetors, recoil housing and exhaust manifold.
2. Remove water pump, and starter recoil cup with water
pump drive pulley and flywheel nut.
3. Install flywheel puller PN 2871043. Use all flywheel bolt
holes. Do no install puller bolts more than 5/16" (7mm) into
flywheel or stator damage may result.
4. Mark stator plate and crankcase for reference when
reassembling the engine.
5. Using a screwdriver, remove stator screws.
6. Remove oil pump, oil pump feed lines from cylinders.
Clean and inspect all components.
7. Remove the cylinder head.
8. Remove head gasket. Note the position of head gasket inlet
and outlet hole sizes for reference during reassembly.
Always replace head gasket after disassembly.
9. Remove cylinder.
10. Remove C-clip retainers from pistons.
11. Using piston pin puller, remove piston pin from piston.
12. Remove crankcase bolts.
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