Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 104 / 289

GENERAL INFORMATION
3.46
9. Tighten the cylinder bolts in three steps in a criss
cross pattern and torque to specifications.
10. Install the two 6 mm bolts.
Cylinder Bolt Torque:
10mm - 46 ft. lbs. (62 Nm)
6mm - 6 ft. lbs. (8 Nm)
CYLINDER HEAD
INSTALLATION
Clean the gasket surfaces on the cylinder head and
cylinder. Remove all traces of old gasket material.
Refer to disassembly photos.
1. Install the cam chain tensioner guide. Be sure
bottom end of guide is located properly in
crankcase.
2. Install the two dowel pins and a new cylinder head
gasket.
3. Place the cylinder head on the cylinder. Apply a
film of engine oil to the cylinder head bolt threads
and washers, and hand tighten the bolts.
The following procedure must be used to torque the
cylinder head properly:
Torque all bolts evenly in a criss cross
pattern
*Torque bolts to 22 ft. lbs. (30 Nm)
*Torque bolts to 51 ft. lbs. (70 Nm)
*Loosen bolts evenly 180
°
(1/2 turn)
*Loosen bolts again another 180
°
(1/2
turn)
*Torque bolts to 11 ft. lbs. (15 Nm)
*From this point, tighten bolts evenly
90
°
(1/4 turn)
*Finally, tighten another 90
°
(1/4 turn)
*Install two 6mm bolts and torque to 6
ft. lbs. (8 Nm)
Guide in
recess
CAM CHAIN/CAMSHAFT
INSTALLATION
Install the cam chain over the crankshaft.
CAUTION: Serious engine damage may result if the
camshaft is not properly timed to the crankshaft.
IMPORTANT CAMSHAFT TIMING NOTE: In order
to time the camshaft to the crankshaft, the piston must
be precisely located at Top Dead Center (TDC).
CAMSHAFT TIMING