Polaris Outlaw 500, Service Manual

Page: 84 / 202

3.37
ENGINE
3
IMPORTANT: Do not use a torch to heat cylinder head
or warpage may result from uneven heating. Head
temperature can be checked with a pyrometer or a
welding temperature stick.
4. When thoroughly heated, place cylinder head on blocks of
wood which will allow the old guides to be removed.
5. Using valve guide driver, drive guides out of the cylinder
head from the combustion chamber side. Be careful not to
damage guide bore or valve seat when removing guides.
6. Place cylinder head on cylinder head table.
NOTE: Be sure cylinder head is still at 212° F (100°
C) before installing new guides.
7. Place a new guide in the valve guide installation tool and
press guide in to proper depth. Check height of each guide
above the cylinder head (A).
NOTE: The guide can also be inserted to the proper
depth using a driver. Inspect the guide closely for
cracks or damage if a driver is used.
8. Allow the cylinder head to cool to room temperature. Apply
cutting oil to the reamer. Guides should be reamed from the
valve spring side of the cylinder head. Ream each guide to
size by turning the reamer clockwise continually. Continue
to rotate reamer clockwise during removal of the tool.
9. Clean guides thoroughly with hot soapy water and a nylon
brush. Rinse and dry with compressed air. Apply clean
engine oil to guides.
Valve Seat Reconditioning
1. Follow the manufacturers instructions provided with the
Valve Seat Reconditioning Kit (
P/N 2200634 ). Abrasive
stone seat reconditioning equipment can also be used.
Keep all valves in order with their respective seat.
NOTE: Valve seat width and point of contact on the
valve face is very important for proper sealing. The
valve must contact the valve seat over the entire
circumference of the seat, and the seat must be the
proper width all the way around. If the seat is
uneven, compression leakage will result. If the seat
is too wide, seat pressure is reduced, causing
carbon accumulation and possible compression
loss. If the seat is too narrow, heat transfer from
valve to seat is reduced and the valve may overheat
and warp, resulting in burnt valves.
2. Install pilot into valve guide.
3. Apply cutting oil to valve seat and cutter.
4. Place 46° cutter on the pilot and make a light cut.
5. Inspect the cut area of the seat:
• If the contact area is less than 75% of the circumference
of the seat, rotate the pilot 180° and make another light
cut.
• If the cutter now contacts the uncut portion of the seat,
check the pilot. Look for burrs, nicks, or runout. If the
pilot is bent it must be replaced.
Valve Guide Height:
.689- .709” (17.5 - 18.0 mm)
Valve Guide Installed Height
Valve Seat Wear Patterns
Too
Wide
Uneven
Good
Too
Narrow