6.15
ENGINE
5. Replace the flywheel onto the crankshaft end and hold the
flywheel with the holding tool (PN 8700229).
6. Torque the flywheel holding nut to 90 ft-lb(122Nm).
7. Replace the recoil basket fasteners to 108 in-lb (12Nm).
8. Replace the recoil housing.
9. Torque the recoil housing fasteners to 108 in-lb (12Nm).
500/600 HO ENGINE
500/600 HO TORQUE SPECIFICATIONS
1 =Apply Loctite 242 to threads of bolt.
2= Apply Pipe sealant to threads.
3= See torque sequence.
600 HO IQ ENGINE REMOVAL
NOTE: Inspect all parts for wear or damage during
disassembly. Replace all seals, o-rings, and gaskets
with Genuine Pure Polaris parts during assembly.
Refer to the ‘INSPECTONS” on page 3.5 for general
inspection procedures.
1. Remove the side panels.
2. Disconnect battery ground (-) if applicable.
3. Turn the fuel valve to the “OFF” position (1).
4. Remove the exhaust system. See “EXHAUST
REMOVAL” on page 3.16
5. Disconnect the CDI box and harness from the air box.
6. Pull up the air box and disconnect the vent lines and coil
connections.
7. Remove the spark plug caps from the spark plugs.
8. Remove the air box.
9. Remove the recoil handle and secure the recoil rope (2).
10. Remove the drive belt, driven clutch and drive clutch.
‘DRIVE CLUTCH REMOVAL” on page 7.10 and
‘DRIVEN CLUTCH REMOVAL” on page 7.20.
Table 6-3:
ENGINE 500/600/600HO
SPARK PLUG 18 ft-lb (24Nm)
CYLINDER HEAD 22ft-lb (30Nm)1,3
BLEEDER SCREW 70 in-lb (8Nm)
THERMOSTAT HOUSING 9 ft-lb (12Nm)
WATER TEMPERATURE SENSOR
18-40ft-lb
(24-54Nm)2
WATER INLET PIPE 75ft-lb (102Nm)2
DETIONATION SENSOR 168 in-lb(19Nm)
CYLINDER BASE NUTS 32 ft-lb (43Nm)3
EXHAUST VALVE COVER BOLTS 12 ft-lb (16Nm)
EXHAUST VALVE NUT 144 in-lb (16Nm)1
EXHAUST MANIFOLD BOLTS 22 ft-lb (30Nm)
CARB ADAPTER BOLTS 108 in-lb (12Nm)
OIL PUMP MOUNTING BOLTS 7 ft-lb (9Nm)
CRANCASE PLUGS 10ft-lb (14Nm)2
WATER PUMP IMPELLER NUT 120 in-lb (14Nm)
WATER PUMP COVER BOLTS 108 in-lb (12Nm)
CRANKCASE 6mm 9ft-lb (12Nm)1,3
CRANKCASE 8mm 22ft-lb (30Nm)1 ,3
CRANKCASE 10mm N/A
ENGINE STRAP to CHASSIS NUT 18ft-lb (24Nm)
ENGINE STRAP to ENGINE BOLT 45 ft-lb (61Nm)
STATOR BOLTS 60 in-lb(7Nm)1
TRIGGER COIL BOLTS 48 in-lb (5Nm)
FLYWHEEL 90ft-lb (122Nm)1
RECOIL CUP BOLTS 108 in-lb (12Nm)
RECOIL COVER COLTS 108 in-lb (12Nm)
DRIVE CLUTCH BOLT 50 ft-lb(68Nm)
7/16” ENGINE MOUNT STRAP BOLTS 45 ft-lb (61Nm)
REAR MOTOR MOUNTS BRACKET
29 ft-lb
(39Nm)
FRONT MOTOR MOUNT PLATE N/A
1
2
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