Polaris 2004-2005 Sportsman 6x6, Service Manual

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GENERAL INFORMATION
3.50
Starter Drive
1. Be sure the washer is positioned on the back of
the drive gear.
Apply Starter Drive
Grease to Bushing
2. Apply starter drive grease to the drive bushing in
the crankcase and all moving surfaces of the
starter drive mechanism. Install the starter drive.
3. Install recoil housing gasket and recoil housing.
Starter Drive Grease:
(PN 2871460)
ROCKER SHAFT/ROCKER
ARM ASSEMBLY
INSTALLATION
1. Assemble rocker arms, rocker shaft, and shaft
supports.
2. Install and tighten rocker arm shaft locating bolt.
3. Apply starter drive grease to the cam lobes and
cam follower surfaces.
4. Rotate the engine until the cam lobes are pointing
downward.
5. Be sure the dowel pins are in place and install the
rocker shaft assembly.
6. Apply a light film of engine oil to the threads of the
bolts and tighten evenly.
Rocker Shaft Support Tower Bolt Torque:
9 ft. lbs. (12 Nm)
Rocker Shaft Locating Bolt Torque:
6 ft. lbs. (8 Nm)
7. Adjust valves according to the valve adjustment
procedure found in Chapter 2, Maintenance.
8. Apply clean engine oil liberally to the valve
springs, cam chain, rocker arms, and camshaft.
9. Place a new rocker cover gasket on the cylinder
head and install the cover and bolts.
Rocker Cover Bolt Torque:
6 ft. lbs. (8 Nm)
THERMOSTAT INSTALLATION
Install the thermostat with one of the air bleed holes
positioned next to the upper thermostat cover bolt
hole as shown.