Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 63 / 289

GENERAL INFORMATION
3.5
SPECIAL TOOLS
PART NUMBER TOOL
DESCRIPTION
2872105
Water Pump
Mechanical Seal
Puller
2200634 Valve Seat
Reconditioning Kit
2870390 Piston Support
Block
2871043 Flywheel Puller
2871283 Crankshaft/Water
Pump Seal Install
Kit
5131135 Water Pump
Install Kit
ENGINE FASTENER TORQUE
PATTERNS
Tighten cylinder head, cylinder base, and crankcase
fasteners in 3 steps following the sequence outlined
below.
6mm
1
2 3
4
6
5
Cylinder Head
Cylinder Base
Pattern
Crankcase
Pattern
1
2
3
4
9
7
6
8
5
10
PISTON IDENTIFICATION
The piston may have an identification mark or the
piston may not have an identification mark for
piston placement. If the piston has an identification
mark, follow the directions for piston placement
below. If the piston does not have an identification
mark, the direction for placement of the piston does
not matter.
Note the directional and identification marks when
viewing the pistons from the top. The letter “F”, “
!
”, “
"
” or : must always be toward the flywheel side
of the engine. The other numbers are used for
identification as to diameter, length and design. Four
stroke engine rings are rectangular profile. See text
for oil control ring upper rail installation. Use the
information below to identify pistons and rings.
Engine
Model No.
Oversize
Available*
(mm)
Piston
Length
Standard
Piston
Identifier
EH50PLE10 .25
.50 72mm C
*Pistons and rings marked 25 equal .25mm (.010
I
)
oversized
Pistons and rings marked 50 equal .50mm (.020
I
)
oversized
COOLING SYSTEM
WARNING: Never remove radiator cap when engine
is warm or hot. The cooling system is under pressure
and serious burns may result. Allow the engine and
cooling system to cool before servicing.
Radiator
Thermostat
Cylinder
Head
Water
Pump
Cylinder
FLOW