Polaris 2007 Two Stroke - 500;600 (Carbureted) Torques; 500;600 (Carbureted) Cylinder Head Torque Pattern

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
67
8
9
10
MAG PTO
12
11
Head Pattern
22 ft-lb (30 N-m)