Assembly - Polaris 2007 Two Stroke Service Manual

Assembly

1. Grease oil pump drive gear area. Seals should be installed
with spring and lip facing inward toward crankshaft.
2. Turn bearing until anti-rotation pins are positioned in the
proper location.
3. Apply 3-Bond sealant to crankcase halves.
4. Torque crankcase bolts following sequence outlined in
beginning of this chapter. Lubricate crankshaft main
bearings through access holes. Torque 8mm Bolts to 17-18
f.-lb (22-23 N-m), and 10mm bolts to 23-25 ft-lb
(32-35 N-m).
5
9
1
12
4
8
CRANKCASE PATTERN
8mm Bolts to 17-18ft.lb. (23-25 N-m)
10mm Bolts 23-25 ft.lb. (32-35 N-m)
7
3
11
2
10
6
= T
5. Install pistons arrow toward flywheel.
6. Install C-clip using installation tool PN 2870773.
7. Install new base gasket. Mount gasket with the white
sealing material facing up.
8. Lubricate rings and pistons with two stroke oil. Install rings
with letter, mark, or beveled side facing upward.
9. Lubricate rings and cylinder with Premium 2 Cycle
Lubricant and compress rings with fingers, aligning end
gaps with locating pins. Install cylinder with a gentle front-
to-back rocking motion, being careful not to damage rings.
10. Install cylinder base nuts in pattern and torque to
27-31 ft-lb (37-43 N-m).
7 1
4
CYLINDER BASE
Cylinder Base Nuts 27-31 ft.lb. (37-43 N-m)
11. Install head gasket. Note proper position of gasket, "UP"
facing upward, small intake hole on right (mag) side, large
hole on left (PTO) side.
ENGINE
5
3
2 6
= T
5.17
5