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

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).
ENGINE 500/600
SPARK PLUG
CYLINDER HEAD
BLEEDER SCREW
THERMOSTAT HOUSING
WATER TEMPERATURE SENSOR
WATER INLET PIPE
DETIONATION SENSOR
CYLINDER BASE NUTS
EXHAUST VALVE COVER BOLTS
EXHAUST VALVE NUT
EXHAUST MANIFOLD BOLTS
CARB ADAPTER BOLTS
OIL PUMP MOUNTING BOLTS
CRANCASE PLUGS
WATER PUMP IMPELLER NUT
WATER PUMP COVER BOLTS
CRANKCASE 6mm
CRANKCASE 8mm
ENGINE STRAP to CHASSIS NUT
ENGINE STRAP to ENGINE BOLT
STATOR BOLTS
TRIGGER COIL BOLTS
FLYWHEEL
RECOIL CUP BOLTS
RECOIL COVER COLTS
DRIVE CLUTCH BOLT
7/16" ENGINE MOUNT STRAP BOLTS
REAR MOTOR MOUNTS BRACKET
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
5
9 1
MAG
3
10
6
Head Pattern
22 ft-lb (30 N-m)
ENGINE
18 ft-lb (24 N-m)
22ft-lb (30 N-m)1,3
70 in-lb (8 N-m)
9 ft-lb (12 N-m)
18-40ft-lb
(24-54 N-m)2
75ft-lb (102 N-m)2
168 in-lb(19 N-m)
32 ft-lb (43 N-m)3
12 ft-lb (16 N-m)
144 in-lb (16 N-m)1
22 ft-lb (30 N-m)
108 in-lb (12 N-m)
7 ft-lb (9 N-m)
10ft-lb (14 N-m)2
120 in-lb (14 N-m)
5
108 in-lb (12 N-m)
9ft-lb (12 N-m)1,3
22ft-lb (30 N-m)1,3
18ft-lb (24 N-m)
45 ft-lb (61 N-m)
60 in-lb(7 N-m)1
48 in-lb (5 N-m)
90ft-lb (122 N-m)1
108 in-lb (12 N-m)
108 in-lb (12 N-m)
50 ft-lb(68 N-m)
45 ft-lb (61 N-m)
29 ft-lb (39 N-m)
8
12
4
PTO
11
2
7
5.23