5.40
Engine Systems
9923396 - 2007-2012 EDGE/Widetrak LX Service Manual
©2011 Polaris Sales Inc.
500EV Crankcase
Disassembly / Assembly Process
1.
Remove the engine from the engine compartment.
2.
Follow the process for removing the cylinder head,
cylinders, pistons, flywheel / recoil housing, and the
water / oil pump.
3.
Remove the intake boots, and reed assemblies.
Discard any seals or gaskets.
4.
Remove the crankcase fasteners then carefully pry
apart the crankcase halves. Discard the PTO and
MAG crankshaft seals.
5.
Clean the two crankcase mating surfaces with
carburetor cleaner and a gasket remover. Flush out
the crankcase.
6.
Reinstall the crankshaft back into the lower crankcase
using two new crankcase seals.
7.
Apply a thin bead of Three Bond 1215 to the lower
crankcase mating surface. Install the upper
crankcase.
8.
Loosely install the crankcase fasteners, then torque to
the specifications at the beginning of the chapter. Use
the correct torque sequence when tightening the
screws.
INTAKE BOOTS
REED STUFFERS
REED ASSEMBLIES
IMPULSE FITTING
OIL INJECTION CHECK VALVES
CRANKCASE
WATERPUMP BUSHING SCREW
DRAIN PLUGS
CYLINDER STUDS
A
B,C
= T
A = 9 Ft.Lbs. (12 Nm)
B = (M8) - 22 Ft.Lbs. (30 Nm) - Apply Loctite 242
C = (M6) - 9 Ft.Lbs. (12 Nm) - Apply Loctite 242
= In. / mm.
Long Studs Height (Exhaust side) = 3.66" (93mm)
Small Stud Height (Intake side) = 2.16" (55mm)
