Polaris 2007 Two Stroke Service Manual page 118

ENGINE
9. Install the crankcase bolts and torque to (550 = 15-18 ft-lb
(25 N-m) (340 = 8mm -23 to 25 N-m, 10mm - 32-35 N-m)
in the pattern shown below.
CRANKCASE TORQUE PATTERN-FUJI
550 only
5
13
9
12
14
8
550 Crankcase Bolts 15-18 ft.lb. (20-25 N-m)
340 Crankcase Bolts: 8mm=17-18 ft-lb (23-25N-m)
10mm=24-26 ft-lb (18-19 N-m)
10. Turn the crankcase over and lubricate crankshaft main
bearings through the access holes.
11. Apply Polaris 2-Stroke engine oil to the wrist pins and the
small end bearings and install the pistons with the arrow on
the piston crown facing the flywheel (MAG) side. This will
orientate the piston so that the piston ring locating pins will
be in the intake side of the engine. Install wrist pins onto
the crankshaft with the piston installation tool (PN
2830386).
12. Lubricate rings and the pistons with Polaris 2-Stroke oil and
install the rings with the letter, mark or beveled side facing
upward.
13. Install the c-clips into the piston so that the opening of the
"C" is positioned at the 12:00 or 6:00 position.
14. Install the reed valves in to the intake of the crankcase.
15. Install new base gaskets.
16. Compress the piston rings and install each cylinder onto the
crankcase.
5.14
7
11
1 3
10
4 2
6
= T
17. Torque the cylinder base nuts to:
CYLINDER BASE TORQUE PATTERN-FUJI
1
3
340 = 17-18 ft.lb. (23-25 N-m)
550 = 25-30 ft.lb. (34-40 N-m)
18. Install a new head gasket with the "EX" facing the exhaust
side. Also make sure that the "UP" is facing the intake side
of the engine. (550 only)
19. Insert the head bolts and torque to:
CYLINDER HEAD TORQUE PATTERN-FUJI
340
1 4
3
2
340 = 18-21 ft.lb. (25-28 N-m)
550 = 17-21 ft.lb. (23-28 N-m)
20. Insert the dowels on the blower housing that match up with
the crankcase (550 only).
21. Route the stator wires harness correctly.
22. Install the flywheel, lock washer, woodruff key, and
flywheel nut onto the shaft.
4
2
= T
550
2
5
4
3
6
1
= T