5.34
ENGINE
1. Remove the spark plugs (1)
2. Remove reed valve assembly. See “Reed Valve
Disassembly” on page 5.3.
3. Remove the recoil and stator assembly. See “Recoil/Stator
Removal” on page 5.7.
4. Remove the fuel rail. See “600/700 CFI Fuel Rail/
Injector(s) Removal/Installation” on page 4.17.
5. Remove the head bolts (5).
6. Remove the head cover (8) and the rubber head seals (9).
7. Remove the head (11) and cylinder o-rings (13).
8. Remove the VES assembly. See “Exhaust Valve
Disassembly” on page 5.3.
9. Remove the cylinder nuts (14) and carefully remove the
cylinders (15) with a slight rocking motion.
10. Support one of the pistons with the piston support block PN
2870390.
11. Remove the c-clips that hold the wrist pin into the piston.
12. Using the piston pin puller PN 2870386 and adapter PN
2871445 remove the piston (wrist) pins, and the piston (16)
and small end bearings (22) from the crankshaft rod.
13. Remove the water/oil pump assembly. See “500/600/700
Water/Oil Pump Cross Shaft Disassembly” on page 5.6.
14. If removing the engine mounting straps (these straps are
mounted to the engine and bulkhead) label the direction and
placement of each engine strap.
15. Remove the cylinder base gaskets (17) and replace them if
damaged.
16. Turn over the crankcase and remove the bottom crankcase
bolts (32).
17. Make sure that cylinder dowels (19) are accounted for.
18. Turn the crankcase assembly back over and remove the top
of the crankcase (21).
19. Remove the crankshaft assembly (24-28), and refer to the
General chapter for general engine component inspections
and measurement procedures. See “INSPECTONS” on
page 3.5.
NOTE: If new cases are to be installed make sure
that the new cylinder studs are installed to the
correct length. See “Cylinder Stud Installation” on
page 5.5.
Engine Assembly
1. Assemble the oil/water pump cross shaft as outlined on
See “500/600/700 Water/Oil Pump Cross Shaft
Assembly” on page 5.6.
2. Set the crankshaft assembly (24-28) into the lower
crankcase (29).
3. Fill the cross shaft section of the lower crankcase with cross
shaft break in lube PN 2872435.
4. Place the top crankcase (21) on top of the lower crankcase
(29) and crankshaft assembly. Make sure that seals (25, 28)
are lined up properly to each case section.
5. Apply Loctite 242 to the threads of the lower crankcase
bolts (32).
6. Assemble the crankcase bolts into the crankcases. Torque
the bolts to 22 ft.lb. (30 N-m). Torque in sequence. See
“600/700 CFI Crankcase Torque Pattern” on page 5.35.
7. Lubricate the small end bearings (21) and the piston pins
with Polaris 2 stroke oil and install the piston onto the
crankshaft with the piston pin removal/installation tool PN
2870386 and adapter PN 2871445.
8. Install new c-clips in the piston grooves with the gap facing
straight up (12:00 position) or straight down (6:00
position). Make sure that the c-clip is fully seated in the
piston groove. Use c-clip installation tool PN 2872622A.
9. Install the piston rings onto the piston with the bevel side
up and the gap facing the piston ring locating pin.
10. Install the base gaskets (17) on the upper crankcase.
11. Lubricate the cylinders and pistons with Polaris 2-stroke oil
and carefully install the cylinder onto the pistons by
squeezing the piston rings onto the locating pins and
rocking the cylinder gently from the intake and exhaust
sides.
12. Install the cylinder base nuts (14) and torque to 32 ft-lb
(43.4 N-m) in the Cylinder Base pattern. See “600/700 CFI
Cylinder Base” on page 5.35.
13. Install cylinder o-rings (13).
14. Install the head (11) onto the cylinders.
15. Install head cover o-rings (9) with the head cover (8) on the
head.
16. Apply Loctite 242 on bolt threads (5) and torque to 22ft-lb
(29 N-m). Torque in the pattern. See “600/700 CFI
Cylinder Head Torque Pattern” on page 5.35.
17. Install VES. See “Exhaust Valve Assembly” on page 5.3.
= T
Head Bolt Torque 22 ft.lb. (30 N-m)
= T
Cylinder base Nut Torque 32 ft.lb. (43 N-m)
= T
Head Bolt Torque 22 ft.lb. (29 N-m)
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