Polaris Outlaw 500, Service Manual

Page: 89 / 202

3.42
ENGINE
Cylinder Head Installation
Clean the gasket surfaces on the cylinder head and cylinder.
Remove all traces of old gasket material.
Refer to disassembly photos.
1. Install the cam chain tensioner guides. Be sure bottom end
of guide is located properly in crankcase.
2. Install the two dowels and a new cylinder head gasket.
3. Place the cylinder head on the cylinder. Apply a film of
engine oil to the cylinder head bolt threads and washers, and
hand tighten the bolts.
The following procedure must be used to torque the cylinder
head properly:
4. Install the two 6 mm bolts and torque to specification.
CYLINDER SERVICE
Cylinder Inspection
1. Remove all gasket material from the cylinder sealing
surfaces.
2. Inspect the top of the cylinder for warp using a straight edge
and feeler gauge.
3. Inspect cylinder for wear, scratches, or damage.
4. Inspect cylinder for taper and out of round with a
telescoping gauge or a dial bore gauge. Measure in two
different directions, front to back and side to side, on three
different levels (1/2” down from top, in the middle, and
1/2” up from bottom).
**TORQUE ALL BOLTS EVENLY IN A
CRISS-CROSS PATTERN
1. Torque bolts to 22 ft. lbs. (30 Nm)
2. Torque bolts to 51 ft. lbs. (70 Nm)
Leave at this torque for 1 minute to allow
gaskets to seat for proper sealing.
3. Loosen bolts evenly 360
o
(1 turn)
4. Torque bolts to 29 ft. lbs. (35 Nm)
5. From this point, tighten bolts evenly 90
o
(1/4 turn)
6. Finally, tighten another 90
o
(1/4 turn)
7. Install two 6 mm bolts and torque to 6 ft.
lbs. (8 N
m)
Cylinder 6 mm Bolt Torque:
6 ft. lbs. (8 Nm)
Cylinder Warp
.002
″
(.05 mm)
1/2” Down From Top of Cylinder
1/2” Up From Bottom
X
X
X
Y
Y
Y
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