2007 Polaris Two Stroke Snowmobile Workshop Repair manual, Page 126Get this manual
ENGINE 123456789101112Remove the spark plugs (1) Remove reed valve assemblySee "Reed Valve Disassembly" on page 5.3Remove the recoil and stator assemblySee "RecoilStator Removal" on page 5.7Remove the head bolts (2)Remove the head cover (10) and the rubber head seals (11)Remove the head (13) and cylinder o-rings (14)Remove the VES assemblySee "Exhaust Valve Disassembly" on page 5.3Remove the cylinder nuts (15) and carefully remove the cylinders (16) with slight rocking motionRemove the c-clips that hold the wrist pin into the pistonUsing the piston pin puller PN PU-45255 remove the piston pins, and the piston (17) from the crankshaft rodRemove the wateroil pump assemblySee "500600700 WaterOil Pump Cross Shaft Disassembly" on page 5.6If removing the engine mounting straps (these straps are mounted to the engine and bulkhead) label the direction and placement of each engine strapRemove the cylinder base gaskets (18) and replace them if damagedTurn over the crankcase and remove the bottom crankcase bolts (31)Turn the crankcase assembly back over and remove the top of the crankcase (20)Remove the crankshaft assembly (22-29), and refer to the General chapter for general engine component inspections and measurement proceduresIf new cases are to be installed make sure that the new cylinder studs are installed to the correct lengthSee "Cylinder Stud Installation" on page 5.5ENGINE 500600 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 716" ENGINE MOUNT STRAP BOLTS REAR MOTOR MOUNTS BRACKET