700/900 Torque Patterns; 700/900 Assembly; 700/900 Water/Oil Pump Cross Shaft Disassembly - Polaris 340 CLASSIC 2006 Manual

ENGINE
19. Refer to the General section form general engine
component inspections and measurement procedures.

700/900 TORQUE PATTERNS

5
9 1
MAG
3
10
6
Head Pattern
22 ft-lb (29.8Nm)
5
15 1
9
MAG
13 3
11
7
Case Pattern
8mm 22ft-lb (29.8Nm)
3 5
MAG
1
7
Cylinder Pattern
40 ft-lb (54.2Nm)

700/900 ASSEMBLY

1. Lubricate all the crankshaft seals (12) with Polaris All
Season grease. Make sure that the seals are positioned
properly with the lip and spring facing inward toward the
center off the crankshaft.
2. Instal the crankshaft assembly in the lower crankcase.
6.12
8
12
4
PTO
11
2
7
8
4 12 14
PTO
10 16
2
6
4
6
PTO
8
2
3. Fill in the cross shaft area with engine assembly lubricant
(PN 2872435).
4. Apply a thin bead of 3 Bond 1215 sealant (PN 2871557)
to the lower case (13) matting surface.
5. Assemble the upper case (9) to the lower case (13),
making sure that the seals and bearings fit in the locations
on the upper case half.
6. Follow the crankcase bolt torque pattern and torque the
lower case bolts to 23 ft-lb (31Nm).
7. Lubricate the piston pin bearings and the piston pins with
Polaris 2 stroke oil and install the piston onto the
crankshaft with the piston pin removal/installation tool.
8. Install new c-clips in the piston grooves with the gap
facing correctly, (MAG c-clip in the 10:00 position) or
(PTO c-clip in the 2:00 position). Make sure that the c-clip
is fully seated in the piston groove.
9. Install the piston rings onto the piston with the bevel side
up and the gap facing the piston ring locating pin.
10. If old base gaskets are damaged, install new ones.
NOTE: New base gaskets have a rib that faces
upward.
11. Lubricate the cylinders and pistons with Polaris 2 stroke
oil and install the cylinders onto the pistons by squeezing
the piston rings onto the locating pins in the piston ring
groove, rock the cylinder gently back and forth until the
cylinder can be installed onto the upper case matting
surface.
12. Install the cylinder base bolts and torque to 34 ft-lb
(46Nm) in the sequence found on page 6.12.
13. Install new head o-rings if the old ones are damaged.
14. Install the head onto the cylinders.
15. Torque the head bolts to 22 ft-lb (29Nm) in the sequence
found on page 6.12
16. Install water pump cover.
17. Install the reeds. See "REED VALVE ASSEMBLY" on
page 6.4
18. Install the fuel rail. See "FUEL RAIL/INJECTOR
REMOVAL" on page 5.3
19. Assemble the recoil/stator. See "700/900 RECOIL/
STATOR ASSEMBLY" on page 6.14
20. Install the front motor mount, and torque the fasteners to
25 ft-lb (34Nm).
700/900 WATER/OIL PUMP CROSS SHAFT
DISASSEMBLY
1. Remove the water pump cover bolts (1)