Polaris Outlaw 500, Service Manual

Page: 79 / 202

3.32
ENGINE
Cylinder Installation
1. Place the dowel pins in the crankcase and install a new
cylinder base gasket.
2. Position the Piston Support Block ( P/N 2870390) beneath
the piston skirt to support the piston during cylinder
installation.
3. Apply clean engine oil to the ring compressor and install
the compressor according to the manufacturer’s
instructions.
IMPORTANT: Verify all ring end gaps are correctly
located.
4. Apply clean engine oil liberally to the cylinder bore and
tapered area of the sleeve. Install the cylinder with a slight
rocking motion until the rings are captive in the sleeve.
5. Remove the ring compressor and support block.
6. Push the cylinder downward until fully seated on the base
gasket.
7. Rotate the crankshaft and position the piston at TDC.
NOTE: If cam chain is installed, hold it up while
rotating the engine to avoid damage to the chain,
drive sprocket teeth, or tensioner blade.
Cam Chain Installation
NOTE: The camshafts, crankshaft sprocket and
clutch basket must be removed to perform this
procedure.
1. Install the cam chain by dropping it down through the
chain room and over the crankshaft sprocket.
2. Use a suitable device to hold the chain in place to keep it
from dropping through the chain room, such as wire or a
hammer handle.
Camshaft Timing
IMPORTANT: CAMSHAFT TIMING NOTE
The Top Dead Center (TDC) mark is used to time the
camshaft to the crankshaft. Follow the procedures
outlined. Refer to the diagram.
1. Apply engine oil or assembly lube to the camshaft main
journals, cam lobes and the automatic compression release
mechanism.
2. Install the crankshaft cam sprocket onto the shaft. Note the
double spline for ease of installation. The alignment mark
should face outward.
PN 2870390
CAUTION
Serious engine damage will result if the camshaft
is not properly timed to the crankshaft.
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