700/900 Liberty Engine Removal - Polaris 340 CLASSIC 2006 Manual

ENGINE

700/900 LIBERTY 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.
NOTE: Make a note of the orientation and placement
of every wire tie, hose clamp and spring clamp
during engine removal.
CAUTION
Wear eye protection to prevent eye injury.
1. Remove the side panels.
2. Disconnect battery ground (-) if applicable.
3. Remove the plenum and boost box. 'IQ 700/900 AIR
INTAKE REMOVAL" on page 12.7
4. Remove the belt. 'DRIVE BELT REMOVAL WITH
TEAM CLUTCH" on page 7.5.
5. Remove the exhaust system. 'EXHAUST REMOVAL"
on page 3.16
6. Remove the drive and driven clutches. 'DRIVE CLUTCH
REMOVAL" on page 7.10 and 'DRIVEN CLUTCH
REMOVAL" on page 7.20
7. Drain coolant. (Drain the coolant, by disconnecting the
hose to the thermostat and apply air pressure to the
thermostat side while holding the disconnected hose into a
container).
6.6
8. Remove the seat. 'SEAT and FUEL TANK" on page 12.4
9. Remove the fuel tank. 'IQ FUEL TANK REMOVAL" on
page 12.5
10. Remove both fender plugs to access the fasteners for the
side braces.
NOTE: Keep track of the orientation and placement
of all fasteners, and cable ties.
11. Remove the left hand side brace and fuel filter.
12. Remove the right hand brace. The middle front fastener
has the hose guide.
13. Remove the two fasteners that hold the oil tank on the
chassis.
14. Drain the oil from the oil tank.
15. Remove the center shaft oil supply line from the oil tank.
16. Remove the fasteners that hold the coolant/oil tank onto
the chassis.
17. Remove the coolant bottle. 'COOLANT TANK
REMOVAL" on page 12.3
18. Remove the oil tank. 'OIL TANK REMOVAL" on
page 12.3
19. Disconnect the exhaust valve hose from the base of the
exhaust valve base, and secure them out of the way.
20. Loosen the throttle adjustment lock nut and remove
throttle cable from the throttle body.
21. Disconnect the throttle cable from the throttle body.
22. Remove the coolant line that goes to the coolant bottle.
NOTE: You may remove the throttle body at this
time or when it is out of the chassis. See
"THROTTLE BODY REMOVAL" on page 5.6
23. Disconnect the water temperature sensor connection (1)
from the harness, and move this harness out of the way.
The water temperature connectors are located in the
convoluted tubing near the cylinder base.
1
24. Remove the cable tie (2) that holds the TPS and water
sensor wires to the stator harness.
25. Disconnect the 4 fuel injector connectors (3) form the