Cylinder Head Removal - Polaris 1999 Sportsman 400 Service Manual

11 0
a. Lift the ratchet (A, Figure 64) , then push the
plunger (B, Fig ure 64) a ll the wa y into the
body. Relea se the ratchet to hold the plun ger
in the co rrect position (F igu re 65) .
b. Install a new gasket (Figu re 66) and install
the tens ioner body (B, Fig u re 41) into the
cy linder block and against the camshaft
chai n.
e. Push the tensioner aga inst the cy linder block
and install the mounting bol ts (A, Figure 41).
Tight en the bolts to the torque spec ificat ion
listed in Ta ble 3 .
d. Install the spring (F igure 40) into the body.
e. Insta ll a new gask et, then ins13 11 the bolt (Fig-
ure 39). Tighten the bolt to the torque specifi-
cation listed in Table 3.
NO TE
The plated links and dots
all
the
sprocket are aligned during the initial
camshaft timing procedure.
After
turni ng the crankshaf t the sam e align-
ment
Dil ly
occ urs infrequently: There-
fore , during Stcp 14. reference the
liming marks on the sprockets, not the
(lVO
plated can/shaft links.
14. Rotate the engine cranks haft two or more revo -
lutions and recheck alignmen t of the timing marks
(Fig ure 58 and Figure 6 1). If the a lignm ent marks
changed after installing the chai n tensioner, remo ve
the tensioner and repeat Steps 3-5.
15. On the right, insta ll a new gasket (Figure 67)
and the cams haft sproc ket cover (F igure 68) . Install
the bo lts a nd tighten securel y.
16. Install the thermo stat hou sing as described in
Cha pter S ix.
17. Insta ll the coolant reservoir as described in
Chapter Six.
18. Install the rocker arm assembly and the cy lin-
der head co ver as described in thi s chapte r.
CYLINDER HEAD
Removal
1.
Remove the cylind er head cove r, rocker ann as-
sembly and the camshaft as desc ribed in this chapter.
2. Remove the carburetor and ex ha ust pipe from
the cylinder head as describ ed in Chapter Six.
3. Loosen the two flange bo lts (A, Figu re 69) in
2-3 stages then re move them .
CHA PTER FOU R
®