700/900 Engine Rebuilding; 700/900 Disassembly - Polaris 340 CLASSIC 2006 Manual

700/900 ENGINE REBUILDING

700/900 DISASSEMBLY

1. Remove the recoil housing and stator. See "700/900
RECOIL/STATOR DISASSEMBLY" on page 6.14
2. Remove the fuel rail. See "FUEL RAIL/INJECTOR
REMOVAL" on page 5.3
3. Remove the throttle body. See "THROTTLE BODY
REMOVAL" on page 5.6
4. Remove the reeds.
DISASSEMBLY" on page 6.3
5. Remove the exhaust valve assembly. 'EXHAUST
VALVE REMOVAL" on page 6.2
6. Remove the head bolts (1).
7. Remove the head (2) and o-rings (3).
1
22(29)
2
3
4
5
12
14
23(31)
See "REED VALVE
6
7
8
9
10
11
13
8. Remove the cylinder bolts (4).
9. Remove the cylinders (5).
10. Remove the MAG side piston c-clips from the pistons.
11. Remove the piston pins using the piston pin removal/
installation tool (PN 2870386).
12. Remove the pistons (6) and pin bearings from the
crankshaft.
13. Remove the base gaskets (7).
14. Account for all the cylinder locating pins (8).
15. Remove the oil pump and all oil lines from the crankcases.
16. Flip the engine over and remove the loser case bolts (14).
17. Separate the upper and lower cases (9,13).
18. Remove the crankshaft assembly (11) from the lower case.
ENGINE
12
6.11