6.29
ENGINE
17. Torque the cylinder base nuts to:
•340 = 17-18 ft-lb (23-25Nm)
•550 = 25-30 ft-lb (34-40Nm)
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.
19. Insert the head bolts and torque to:
•340 = 18-21 ft-lb (25-28 Nm)
•550 = 17-21 ft-lb (23-28 Nm)
20. Insert the dowels on the stator housing that match up with
the crankcase.
21. Route the stator wires harness correctly.
22. Install the flywheel, lock washer, woodruff key, and
flywheel nut onto the shaft.
23. Torque the flywheel nut to:
• 340 = 61-70 ft-lb (83-90Nm)
• 550 = 58-72 ft-lb (79-98Nm)
24. Install the recoil cup onto the flywheel.
25. Install the recoil cover.
26. Install the CDI box on the flywheel cover.
27. Insert the vibration dampener in between the cooling fins
that are located between the two cylinders on the intake
side.
28. Install the two fan deflectors.
NOTE: Make sure that the fan deflectors interlock
before tightening down.
29. Install the oil pump onto the lower case half.
NOTE: Install all oil pump shims.
30. Apply Blue Loctite 243 to the oil pump mounting screw
threads and torque to 48-72 in-lb (5.5-8.3Nm).
31. Route each oil line on the oil pump in the correct positions.
32. Install intake boots.
33. Install the boot clamps onto the boots.
34. Install the carburetors onto the boots.
35. Tighten the boot clamps.
36. Insert engine into the chassis.
500 FUJI
DISASSEMBLY
NOTE: Inspect all parts for wear or damage during
disassembly. Replace all seals, O-rings, and gaskets
with Genuine Polaris parts during assembly. Refer to
General Section for Inspection Procedures.
1. Remove carburetors, recoil housing and exhaust manifold.
2. Remove water pump, and starter recoil cup with water
pump drive pulley and flywheel nut.
3. Install flywheel puller PN 2871043. Use all flywheel bolt
holes. Do no install puller bolts more than 5/16, (7mm)
into flywheel or stator damage may result.
CYLINDER BASE TORQUE PATTERN-FUJI
1
3
4
2
CYLINDER HEAD TORQUE PATTERN-FUJI
5
3
2
1
4
6
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