Polaris SPORTSMAN 600 2003, Service Manual, Page: 81 / 262

ENGINE
3.29
CYLINDER REMOVAL
1. Follow engine disassembly procedures to
remove rocker cover and cylinder head.
2. Tap cylinder (A) lightly with a rubber mallet in the
reinforced areas only until loose.
3. Rock cylinder forward and backward while lifting it
from the crankcase, supporting pistons and
connecting rods.
Support pistons with Piston
Support Block ( PN 2870390 ).
A
VALVE LIFTER
REMOVAL/INSPECTION
1. Remove the valve lifter’s by reaching into the
crankcase and pushing the lifter up through the
lifter bore by hand.
2. Thoroughly clean the lifters in cleaning solvent
and wipe them with a clean lint-free cloth.
3. Mark the lifters with a white pen if using the lifters
for reassembly. This will ensure that the lifters are
properly placed during engine reassembly.
Mark the Hydraulic Lifter
4. Check the lifters for wear or scores.
5. Check the bottom end of lifter to make sure that it
has a slight convex.
6. If the bottom surface has worn flat, it may be used
with the original camshaft only.
Inspect Hydraulic Lifter
NOTE: Lifters that are scored, worn, or if the bottom
is not smooth should be replaced with new lifters and
cam as an assembly. If replacing the lifters, the
camshaft should also be replaced.
PISTON REMOVAL
1. Remove circlip (A). Mark the piston with a white
pen to ensure proper orientation (if reused) during
assembly.
A
Mark the piston
NOTE: If the pistons are to be reused, reassemble
the pistons in the same cylinder and direction from
which they were removed.
NOTE: New pistons are non--directional and can be
placed in either cylinder.
2. Remove piston circlip and push piston pin out of
piston. If necessary, heat the crown of the piston
slightly with a propane torch.
CAUTION: Do not
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