500/600 Ho Engine; 500/600 Ho Torque Specifications; 600 Ho Iq Engine Removal - Polaris 340 CLASSIC 2006 Manual

5. Replace the flywheel onto the crankshaft end and hold the
flywheel with the holding tool (PN 8700229).
6. Torque the flywheel holding nut to 90 ft-lb(122Nm).
7. Replace the recoil basket fasteners to 108 in-lb (12Nm).
8. Replace the recoil housing.
9. Torque the recoil housing fasteners to 108 in-lb (12Nm).

500/600 HO ENGINE

500/600 HO TORQUE SPECIFICATIONS

Table 6-3:
ENGINE
SPARK PLUG
CYLINDER HEAD
BLEEDER SCREW
THERMOSTAT HOUSING
WATER TEMPERATURE SENSOR
WATER INLET PIPE
DETIONATION SENSOR
CYLINDER BASE NUTS
EXHAUST VALVE COVER BOLTS
EXHAUST VALVE NUT
EXHAUST MANIFOLD BOLTS
CARB ADAPTER BOLTS
OIL PUMP MOUNTING BOLTS
CRANCASE PLUGS
WATER PUMP IMPELLER NUT
WATER PUMP COVER BOLTS
CRANKCASE 6mm
CRANKCASE 8mm
CRANKCASE 10mm
ENGINE STRAP to CHASSIS NUT
ENGINE STRAP to ENGINE BOLT
STATOR BOLTS
TRIGGER COIL BOLTS
FLYWHEEL
RECOIL CUP BOLTS
RECOIL COVER COLTS
DRIVE CLUTCH BOLT
7/16" ENGINE MOUNT STRAP BOLTS
REAR MOTOR MOUNTS BRACKET
FRONT MOTOR MOUNT PLATE
1 =Apply Loctite 242 to threads of bolt.
2= Apply Pipe sealant to threads.
3= See torque sequence.

600 HO IQ 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.
1.
2.
3.
500/600/600HO
18 ft-lb (24Nm)
22ft-lb (30Nm)1,3
70 in-lb (8Nm)
9 ft-lb (12Nm)
18-40ft-lb
(24-54Nm)2
75ft-lb (102Nm)2
168 in-lb(19Nm)
32 ft-lb (43Nm)3
12 ft-lb (16Nm)
4.
144 in-lb (16Nm)1
22 ft-lb (30Nm)
5.
108 in-lb (12Nm)
7 ft-lb (9Nm)
6.
10ft-lb (14Nm)2
120 in-lb (14Nm)
7.
108 in-lb (12Nm)
8.
9ft-lb (12Nm)1,3
9.
22ft-lb (30Nm)1,3
N/A
18ft-lb (24Nm)
45 ft-lb (61Nm)
60 in-lb(7Nm)1
48 in-lb (5Nm)
90ft-lb (122Nm)1
108 in-lb (12Nm)
108 in-lb (12Nm)
50 ft-lb(68Nm)
45 ft-lb (61Nm)
29 ft-lb
(39Nm)
N/A
10. Remove the drive belt, driven clutch and drive clutch.
Remove the side panels.
Disconnect battery ground (-) if applicable.
Turn the fuel valve to the "OFF" position (1).
Remove the exhaust
REMOVAL" on page 3.16
Disconnect the CDI box and harness from the air box.
Pull up the air box and disconnect the vent lines and coil
connections.
Remove the spark plug caps from the spark plugs.
Remove the air box.
Remove the recoil handle and secure the recoil rope (2).
'DRIVE CLUTCH REMOVAL" on page 7.10 and
'DRIVEN CLUTCH REMOVAL" on page 7.20.
ENGINE
1
system. See "EXHAUST
2
6.15