Cylinder Head Assembly - Polaris Outlaw 500 Service Manual

Cylinder Head Assembly

CAUTION
Wear eye protection during assembly.
NOTE: Assemble the valves one at a time to
maintain proper order.
1. Install new valve seals on valve guides.
2. Apply engine oil to valve guides and seats.
3. Coat valve stem with assembly lube.
4. Install valve carefully with a rotating motion to avoid
damaging valve seal.
5. Install spring washers. Dip valve springs and retainer in
clean engine oil and install springs with closely spaced coils
(B) toward the cylinder head.
B
Spring Washer Located
Below Assembly
6. Place spring retainer on and install valve spring compressor
(A). Compress springs only enough to allow split keeper
installation and prevent loss of spring tension. Install split
keepers with the gap even on both sides.
7. Repeat procedure for remaining valves.
8. When all valves are installed, tap lightly with soft faced
hammer on the end of the valves to seat the keepers.
9. Install the shims and buckets for each valve in the order they
were removed.
10. Check valve clearance with engine at Top Dead Center
(TDC).
NOTE: Repairs such as valve grinding or valve
replacement will require re-shimming for proper
valve clearance. Use the chart provided on page 3.40
to determine the appropriate shim thickness.
Valve Clearance (Engine Cold):
Intake: .006
Exhaust: .010" (.27 mm)
+/- .0019
ENGINE
A
"
(.15 mm)
"
(.05 mm)
3.41
3