Polaris 2007 Two Stroke - 500;600 (Carbureted) Cylinder Base; 500;600 (Carbureted) Crankcase Torque Pattern; 500;600 (Carbureted) Engine Assembly

5.24
ENGINE
500/600 (Carbureted) Cylinder Base
500/600 (Carbureted) Crankcase Torque
Pattern
500/600 (Carbureted) Engine Assembly
1. Assemble the oil/water pump cross shaft as outlined on
See “500/600/700 Water/Oil Pump Cross Shaft
Assembly” on page 5.6.
2. Set the crankshaft assembly (22-29) into the lower
crankcase (27).
3. Fill the cross shaft section of the lower crankcase with cross
shaft break in lube PN 2872435.
4. Place the top crankcase (20) on top of the lower crankcase
and crankshaft assembly. Make sure that seals are lined up
properly to each case section.
5. Apply Loctite 242 to the threads of the lower crankcase
bolts (31).
6. Assemble the crankcase bolts into the crankcases. Torque
the bolts to 22 ft.lb. (30 N-m). See “500/600 (Carbureted)
Crankcase Torque Pattern” on page 5.24.
7. Lubricate the small end bearings (21) and the piston pins
with Polaris 2 stroke oil and install the piston onto the
crankshaft with the piston pin removal/installation tool PN
PN PU-45255.
8. Install new c-clips in the piston grooves with the gap facing
straight up (12:00 position) or straight down (6:00
position). Make sure that the c-clip is fully seated in the
piston groove. Use c-clip installation tool PN 2872622A.
9. Install the piston rings onto the piston with the bevel side
up and the gap facing the piston ring locating pin.
10. Install the base gaskets (18) on the upper crankcase.
11. Lubricate the cylinders and pistons with Polaris 2-stroke oil
and carefully install the cylinder onto the pistons by
squeezing the piston rings onto the locating pins and
rocking the cylinder gently from the intake and exhaust
sides.
12. Install the cylinder base nuts (15) and torque to 32 ft-lb(43.4
N-m) in the Cylinder Base pattern. See “500/600
(Carbureted) Cylinder Base” on page 5.24.
13. Install cylinder o-rings (14).
14. Install head cover o-rings (11) with the head cover (10) on
the head.
15. Apply Loctite 242 on head bolt threads (2) and torque to
22ft-lb (29 N-m).
16. Install VES. See “Exhaust Valve Assembly” on page 5.3.
= T
Head Bolt Torque 22 ft.lb. (30 N-m)
7
3
5
1
2
6
4
8
Cylinder Base Pattern
32 ft-lb (43 N-m)
MAG
PTO
11
9
7
5
1
3
2
4
6
8
12
10
14
13
Case Pattern
(Bolts 1 - 14) 22ft-lb (30 N-m)
PTO
MAG
15
(Bolt 15) 5 ft-lb (7N-m)
= T
Cylinder base Nut Torque 32 ft.lb. (43 N-m)
= T
Head Bolt Torque 22 ft.lb. (29 N-m)