Polaris Outlaw 500, Service Manual

Page: 85 / 202

3.38
ENGINE
• If the contact area of the cutter is in the same place, the
valve guide is distorted from improper installation and
must be replaced. Be sure the cylinder head is at the
proper temperature and replace the guide.
• If the contact area of the initial cut is greater than 75%,
continue to cut the seat until all pits are removed and a
new seat surface is evident.
NOTE: Remove only the amount of material
necessary to repair the seat surface.
6. To check the contact area of the seat on the valve face, apply
a thin coating of Prussian Blue™ paste to the valve seat. If
using an interference angle (46°) apply black permanent
marker to the entire valve face (A).
7. Insert valve into guide and tap valve lightly into place a few
times.
8. Remove valve and check where the Prussian Blue™
indicates seat contact on the valve face. The valve seat
should contact the middle of the valve face or slightly
above, and must be the proper width (refer to the wear limits
for proper seat width).
• If the indicated seat contact is at the top edge of the
valve face and contacts the margin area it is too high on
the valve face. Use the 30° cutter to lower the valve
seat.
• If too low use the 60° or 75° cutter to raise the seat.
When contact area is centered on the valve face,
measure seat width.
• If the seat is too wide or uneven, use both top and
bottom cutters to narrow the seat.
• If the seat is too narrow, widen using the 45° cutter and
re–check contact point on the valve face and seat width
after each cut.
NOTE: When using an interference angle, the seat
contact point on the valve will be very narrow, and is
a normal condition. Look for an even and continuous
contact point on the black marker, all the way
around the valve face.
9. Clean all filings from the area with hot soapy water, rinse,
and dry with compressed air.
10. Lubricate the valve guides with clean engine oil, and apply
oil or water based lapping compound to the face of the
valve.
NOTE: Lapping is not required with an interference
angle.
11. Insert the valve into its respective guide and lap using a
lapping tool or a section of fuel line connected to the valve
stem.
12. Rotate the valve rapidly back and forth until the cut sounds
smooth. Lift the valve slightly off of the seat, rotate 1/4 turn,
and repeat the lapping process. Do this four to five times
until the valve is fully seated, and repeat process for the
other valve(s).
13. Clean cylinder head, valves, and camshaft oil supply
passages thoroughly.
Valve Seat Width:
Intake Std: .028” (.7 mm)
Limit: .055” (1.4 mm)
Exhaust Std: .039” (1.0 mm)
Limit: .071” (1.8 mm)
Seat Contact
Width
Seat 45
o
or 46
o Top 30
o
Bottom 60
o
or 75
o
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