600/700 Cfi Cylinder Head Torque Pattern; 600/700 Cfi Cylinder Base; 600/700 Cfi Crankcase Torque Pattern; 600/700 Cfi Engine Installation - Polaris 2007 Two Stroke Service Manual

600/700 CFI Cylinder Head Torque Pattern

5
9 1
MAG
3
10
6
Head Pattern
25 ft-lb (34 N-m)

600/700 CFI Cylinder Base

5
3
MAG
1
7
Cylinder Base Pattern
32 ft-lb (43 N-m)

600/700 CFI Crankcase Torque Pattern

5
1
9
16
MAG
3
11
15
7
Case Pattern
22ft-lb (30 N-m)

600/700 CFI Engine Installation

1. Make sure that you have the engine assembled in the state
that it was when it was removed. This includes all the
coolant hoses, oil lines, and electrical wires.
2. Fill oil lines with 2 stroke engine oil when assembling.
3. Clean the oil residue and debris out of the engine
compartment.
4. To assure a smooth transition of the loose engine into the
engine compartment, secure all loose hoses that are in side
the engine compartment.
NOTE: You may need a helper with the installation
of the throttle and oil cables.
8
12
4
PTO
2 11
7
4
6
PTO
8
2
8
4 12 14
PTO
10 13
2
6
5. Place the engine on the shock tower brace and hold engine
at this point.
6. With the throttle bodies separated from the intake adapters,
route the throttle cable behind the fuel rail and insert the
throttle cable into the throttle pulley located in the center
of the throttle bodies.
7. Insert the throttle body into the adapters and tighten the
clamps in the orientation as shown below.
8. Adjust the throttle cable adjuster nut so that you have the
correct throttle free play. See "Throttle Lever Free Play -
Non CFI" on page 3.18.
9. Place the oil cable into the oil pump arm. The oil pump arm
has a slot (1) in the back to slide the cable through for
installation. The plastic end of the throttle cable is inserted
so that the large flat is facing the engine and the small end
is facing the out side.
ENGINE
5
1
5.35