Polaris 2007 Two Stroke User Manual

5.25
ENGINE
5
500/600 (Carbureted) Recoil/Stator Removal
1. Remove the recoil cover (2).
2. Remove the recoil basket bolts (1) and the recoil basket (4).
3. Using a strap wrench PN PU-45419 hold the flywheel while
taking the flywheel nut (5) and washer (6) off.
4. Using the Flywheel Puller PN 2871043, thread the puller
bolts into the flywheel. Do not install puller bolts more than
5/16, (7mm) into flywheel threads or stator damage may
result.
5. Tighten the center bolt and remove the flywheel (7).
6. Note the ignition timing marks that match up with the stator
to the crankcase or scribe additional marks for reference for
assembly.
7. Remove the stator bolts (8), and remove the stator (9). Be
careful when removing the wires of the stator.
500/600 (Carbureted) Recoil/Stator
Installation
NOTE: Inspect all parts for wear or damage during
disassembly. Replace all seals, o-rings, and gaskets
with Genuine Pure Polaris parts during assembly.
Refer General chapter for general inspection
procedures.
1. Install the stator (9) and align the timing marks that was
noted earlier.
2. Apply Loctite 242 to the first few threads of the stator bolts
(8) and torque to 5 ft-lb (7 N-m).
3. Install the flywheel (7) so that it matches up with the index
of the woodruff key.
4. Apply Loctite 242 to the threads of the flywheel nut (5) and
place the washer (6) and nut onto the end of the crankshaft.
5. Holding the flywheel with the strap wrench, torque the
flywheel nut to 90 ft-lb (122 N-m).
6. Install the recoil basket (4) and the recoil basket bolts (3)
on the flywheel and torque the bolts to 9 ft-lb (12 N-m).
7. Install recoil assembly (2) and torque the recoil assembly
bolts (1) to 9 ft-lb (12 N-m).
500/600 (Carbureted) Engine Installation
1. Make sure that you have the engine assembled so that it is
in the same state as it was when it was removed.
2. Place the engine on the shock tower bar and install the oil
pump cable.
3. Adjust the oil cable line so that the line is even (1) with the
index mark.
1
2
4
5
6
7
8
9
3
9 ft-lb
90 ft-lb
5 ft-lb
(12 N-m)
(7 N-m)
(122 N-m)
1

Polaris 2007 Two Stroke Specifications

General

Brand	Polaris
Model	2007 Two Stroke
Category	Snowmobiles
Language	English