Polaris Outlaw 500, Service Manual

Page: 83 / 202

3.36
ENGINE
NOTE: To prevent loss of tension, do not compress
the valve springs more than necessary.
4. Remove spring retainer, inner and outer springs and spring
washer.
NOTE: The valve springs should be positioned with
the tightly wound coils against the cylinder head (B).
5. Push valve out, keeping it in order for reassembly in the
same guide.
6. Measure free length of the inner and outer springs with a
Vernier caliper. Check springs for squareness. Compare to
specifications. Replace inner and outer springs as a set if
either measurement is out of specification.
7. Remove the valve seals.
NOTE: Replace seals whenever the cylinder head is
disassembled. Hardened, cracked or worn valve
seals will cause excessive oil consumption and
carbon buildup.
Cylinder Head Valve Guide / Valve Seat
Inspection
Inspect valve seats in cylinder head for pitting, burnt spots,
roughness, and uneven surface. If any of the described
conditions exist, the valve seat must be reconditioned.
If the
valve seat is cracked the cylinder head must be replaced.
NOTE: Servicing the valve guides and valve seats
requires special tools and a thorough knowledge of
reconditioning techniques. Follow the instructions
provided in the cylinder head service tool kit.
Valve Guide Removal / Installation / Ream
1. Remove all carbon deposits from the combustion chamber,
valve seat and valve guide area before attempting to
remove valve guides.
IMPORTANT: Carbon deposits are extremely
abrasive and may damage the valve guide bore when
guides are removed.
2. Place new valve guides in a freezer for at least 15 minutes
while heating cylinder head.
3. Heat cylinder head in an oven or use a hot plate to bring
cylinder head temperature to 212° F (100° C).
A
B
Spring Washer Located
Below Assembly
Inner 1.575” (40.0 mm)
Outer 1.650” (41.9 mm)
CAUTION
Wear the proper safety equipment when
performing cylinder head service. Valve guide
replacement will require heating of the cylinder
head. Wear safety gloves to prevent burns.
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