5.32
Engine Systems
9923396 - 2007-2012 EDGE/Widetrak LX Service Manual
©2011 Polaris Sales Inc.
Cylinder Assembly
Disassembly / Assembly Process
1. Using an siphon pump, remove enough engine
coolant from the fill tube to lower the coolant level
below the cylinder block.
2. Remove the cylinder head. Discard the head gasket.
3. Remove the exhaust system, carburetors, and water
pump assembly. Discard all o rings and gaskets.
4. Remove the nuts securing the cylinder block to the
crankcase. Remove the block, then discard the base
gasket.
5. Carefully inspect the cylinder block and crankcase for
warping.
6. When installing a new cylinder base gasket, install
with sealing surface up.
7. Apply a liberal amount of two-stoke engine oil to each
piston assembly and each cylinder bore. Carefully
install each piston while making sure each piston ring
is centered at each piston ring locating pin.
8. When installing a new head gasket, install with “UP”
located on the intake-side of engine and readable
when looking down at the engine.
9. Use new exhaust gaskets and intake o rings when
installing components.
10. When refilling cooling system, follow procedures
outlined in Maintenance chapter.
CYLINDER HEAD
EXHAUST GASKET
CYLINDER BLOCK
CYLINDER BASE GASKET
OIL INJECTOR FITTING
SCREW CLAMP
COOLANT OUTLET PIPE
INTAKE BOOT
THERMO SWITCH
CYLINDER HEAD GASKET
O RING
Fastener Torque Note
Cylinder Base
Nuts
27 - 32 ft.lbs.(37 - 43
Nm)
Cylinder Head
18 - 20 ft.lbs. (25 -27
Nm)
Thermoswitch
Apply pipe sealant
to threads.
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