Mighty Quinn

It then ,was time to put the pistons on ,& you can plainly see all the arrows pointing toward the mag side,for this polaris 680.



After the pistons were installed ,the new gaskets were applied with a small bead of 518(Permatex)loctight gasket maker.To the very clean bottom end surface.



With the piston bearings,pin,rings,pistons, & the liner of the cylinder walls were all lubed with 2 stroke
oil ,the cylinders were ready to be droped in & torqued to specs.



All heads are in place ,& all the arrows for install on top of the head point toward the intake.The water pump was also installed at this time ,with all new gaskets & oil ring.



Now it was time for a final clean,inspect ,& intsall of all the new oil rings for the cyl. head & torque to specs. When I torque anything down ,I always use a three step method till the final click of the torque wrench,then a double check with a final pass.

Mighty Quinn

The stator was then set into place with line & arrow lined up at the twelve O clock position ,& the bolts were snuged in with (blue ) 242 Loctight (Permatex). The trigger coil was also set to spec with a feeler gauge.



With the flywheel in place & torqued down ,I then set the trigger coil with a feeler gauge.Note: DO NOT apply any shaft race locking compound ,or any loctight to the shaft .You will be sorry !



Now with the flywheel in place ,the recoil coul now be installed. With a clean up of laquor thinner ,a scuff with a scotch brite pad, & some engine alumi. paint ,the starter looked new again. Ya.. I thought of polishing it to a chrome finish ,but that would take to long.



The reed valve were next,cleaned & inspected , I was very suprised that there are in this good of shape ,for being 17 years old that is.No bending cracking,or chipping of any kind.



Now that the reeds were in place & torqued ,the head covers could now be put into place . With the bolts painted & a little dremal work to the fines on the covers ,this motor was starting to look like new again.

Mighty Quinn

With this pic you will see that the oil pump,coils & fuel pump assembly, & the coolant rail on top of the heads was installed & ready for the 38mm Mikuni carbs .



After complete disasemble ,cleaning & reasemble these Mikuni's were ready for install.



The pic shows the carbs ,fuel lines ,& cables all installed. The motor mounts with all new front upper & lower rubbers this thing is ready for the major drop in.

Mighty Quinn

Yesterday I put on the other new set of trottle cables to see if there was any differance, well... there was'nt same thing,all ajusting nuts are bottemed out & the rpm is 4000 for idle .This is the most frustrating part of this buildThose cables shouln't even be sold ,2 sets & they are the same ,will take them back for refund ! Don't know if (HI-FLEX) still makes them for this sled (the original from Polaris)?

Skid

Nice work.....also like the brand of carb cleaner you use. You know, the stuff in the gold can with the black label.
Just cleaned the carbs on my ultra and had some issues with adjusting the cables and idle. Even with the factory Polaris cables I had the adjusters within 1/8 inch of being bottomed out. Must have something to do with the 38mm carbs although I never had a problem with the XLTs 38mm carbs.

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94 Polaris XLT - XTRA 10, Ski Skins, 3" riser
97 Polaris Ultra
96 Ski Doo Formula III 600 (sold)
97 Polaris XLT Limited - XTRA 12 (My Son's)
80 Kawasaki Intruder (sold)
72 Polaris 340 Colt SS (sold)

Mighty Quinn

Thanks...well went to Polaris yesterday & the factory cables are no longer avalable.This is really starting to suck.

white lightning

You can look around at used sled parts on the web and you should be able to find exactly what youre looking for. Even on EBAY. WL

joshkidner

That engine is extremly clean!! Good job! Like WL said check ebay!

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1987 chasis with 1985 597cc under the hood. Xtra-10, fox shocks, and a whole lotta speed!

Mighty Quinn

Thanks once again guys! Makes me feel like I did do something right with what I had to work with .Well ... I'll check out ebay & then I think I have an idea about the new cable that I have still. I was thinking of taking the adjusting nuts that are on the cables,take them to a grinder wheel ,or belt sander & file them just a little bit thinner to get my adjustment . I hope this might work ,cuz I just need that much more to make it workHummm...It's worth a try . right?

Oh ya ,I don't have any pics of the motor in the sled yet , or even the sled ,? Duuhhh what was I thinking of ? Get some before this weekend I hope. Poker rally is this Saturday, got to have it running prectine for that ! Frick... time is ticking !

white lightning

dhridenh

keep posting i need these pics hahaha what are the torque specs on the jugs and heads its nice to see these pics because my engine i got was torn down so its nice to see them i just got my new pistons in today spi's

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94 polaris Indy 500 EFI SKS Snow King Special l/c and 95 polaris Indy Trail 500 f/c ooo yea love polaris BRAAAAPP

dhridenh

also on my oil pump i have a extra line off if it does that go to the crank or what and how do i get oil to the lines once i have it together
do i get oil up there be for the start or should i premix the gas to get it running then it should pump to the intake

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94 polaris Indy 500 EFI SKS Snow King Special l/c and 95 polaris Indy Trail 500 f/c ooo yea love polaris BRAAAAPP

Mighty Quinn

Cylinder jug base nuts are 24-28 ft.lbs.
Cylinder head bolts are 24-26 ft.lbs.
Cylinder head cover bolts 17-20 ft.lbs.
Cylinder head torque sequece is as follows ,Start #1 at 6 'O'clock ,#2 at 12 'O'clock , #3 at 7 'O'clock , #4 at 2 'O'clock , #5 at 10 'O'clock , #6 at 4 'O'clock.
The oil lines should have three bango fittings to go on the side of the reeds. The bigger inlet on the pump from the tank. Once all your lines are hooked up & the motor is in place crack the hex bleeder screw on the pump it will let the air out till the oil starts to come,then close bleeder screw.I would do this a few times to make sure.Yes add 50:1 mix in the tank., before you start keep pulling it over till you can notice oil coming through the lines ,may take 100 pulls .
Not sure about this forth oil line your taking about?

Ok.. think I found where your forth oil line goes ,PTO side top of crankcase. 97' SPX had this great addon.

dhridenh

hmm i dont see a place to up it tho thats my problem i will take pics of it and show u what i got

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94 polaris Indy 500 EFI SKS Snow King Special l/c and 95 polaris Indy Trail 500 f/c ooo yea love polaris BRAAAAPP

dhridenh

some pics

Attached Thumbnails

         

__________________
94 polaris Indy 500 EFI SKS Snow King Special l/c and 95 polaris Indy Trail 500 f/c ooo yea love polaris BRAAAAPP

Mighty Quinn

The second pic shows where the oil line is suppost to go ,in that hole PTO side,but there is nothing to attach it to ,weird? Your going to have to find out what is suppost to go in there & how? Brass fitting I'm guessing? Why would it be gone? Something fishy is going on here?

Your going to have to get a pic from some where ,& or from some buddy !

dhridenh

Well u said the other sleds don't have it as in the others 700s so what if I plug the hole and the line or do u think I should find a fitting and put it on the sled

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94 polaris Indy 500 EFI SKS Snow King Special l/c and 95 polaris Indy Trail 500 f/c ooo yea love polaris BRAAAAPP

Mighty Quinn

It would be to your benafit if that oil line was hooked back up . Oiling the PTO side crank bearing with it's own oil line,I wish I had that on my 96' .

Mighty Quinn

Yesterday was a good turn out on the poker rally 350 riders .I think my sled could of been the only Ultra there ,lot of newer machines.

Friday night I achived to get my cables to to finnally adjust, grinding down the nuts both sides did the trick.

Belt was squeeling at idle ,tried to adjust secondary to compansate for the new belt to the #1 on the adjuster ?

The motor pulled strong, did a 150 km. poker run yesterday -20 celceus (crispy)!

dhridenh

on the pic with the coils and the back side of the engine with the 4 hoses coming from the fuel pump the one long hose that has no home does that go to the nipple sticking out from the bottom of the crank case as the vacume line for the fuel pump because i need to know also i have a random black wire on the middle coil thats sticking up is that a ground for that and one of the other coils or what i will take pics and post

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94 polaris Indy 500 EFI SKS Snow King Special l/c and 95 polaris Indy Trail 500 f/c ooo yea love polaris BRAAAAPP