Cylinder Block Removal - Polaris 1999 Sportsman 400 Service Manual

ENG INE TOP END
®
119
CAUTION
Any comp ound left on the valves or
the cylinder head will end lip in the
eng ine and cause wear and damage.
8. Install the valve asse mblies as described in this
chapter.
9. Perform the So/vent Test as described in this
chapter to check the valve seating abilit y.
NOTE
This solvent test does not ensure
long-term durability or maxim um
power: I f merely ensures maximum
compression
will
be available
011
ini-
tial start-up afte r reassembly.
CYLINDER BLOCK
Removal
I. Remove the cylinder head cove r, rocke r arm as-
sembly, camshaft and cylinder head (A, Figure 95)
as described in this chapter.
2. Loose n the banjo bo lts at each end of both oil
pipes (F igure 96). Remove the two banjo bolts and
two scaling washers at each end of the oil pipe. Re-
move the oil pipe and place in a reclosab le plastic
bag along with the banj o bolts and sea ling washers
to keep them clean.
3. Repea t Step 2 for the remaining oil p ipe.
4. Loosen the clamp screw (B, Figur e 95), then
disconnect the coo lant hose from the cy linder inlet
fitting.
5. Remove the two 6m m bolts (Figure 97) from the
right side of the cylinder.
6. [f still in place, remove the ca mshaft front chain
guide (Figure 98).
7. If still in place , remove the cylinder head gasket
(Figu re 99) from the top of the cylinder block to ex-
pose the four cylinder block mounting bolts.
8. Loose n eac h of the four cylinder block base bolts
(Figu re 100) in a crisscross pattcrn 1/4 tum at a
time. Remove all four bo lts (F igu re 101).
NOTE
The pisto n should slide smoothly in
the cylinder bore and only light taps
sho uld be requ ired to release the cyl-
inderfrom the crankc ase.
a