Crankcase Disassembly - Polaris Sportsman 850 Service Manual

8. Clean all filings from the area with hot soapy water.
Rinse and dry with compressed air.
9. Lubricate the valve guides with clean engine oil, and
apply oil or water based lapping compound to the
face of the valve.
NOTE
Lapping not required if an interference angle
reconditioning method is used.
10. Insert the valve into its respective guide and lap
using a lapping tool or a section of fuel line
connected to the valve stem.
11. Rotate the valve rapidly back and forth until the cut
sounds smooth. Lift the valve slightly off of the seat,
rotate 1/4 turn, and repeat the lapping process. Do
this four to five times until the valve is fully seated,
and repeat process for the other valve(s).
12. Thoroughly clean cylinder head and valves.

CRANKCASE DISASSEMBLY

CAUTION
The rotor contains powerful magnets. Use caution
when removing and installing the stator cover. DO NOT
place fingers between cover and crankcase at any time
during the removal / installation process or injury could
result.
CAUTION
Do not attempt to lift the upper crankcase / cylinder
from the lower crankcase for piston / ring access
without first removing the lower crankcase and
connecting rod caps from the crankshaft. Pistons must
be removed through the top of the cylinders with the
connecting rod attached.
1. Remove cylinder head (beginning on page 5.27,
page 3.47).
ENGINE / COOLING SYSTEM
2. Remove all water pump cover screws
w
cover screws , noting location of hose retainer
3. NOTE: Water pump cover removal is not required
unless water pump or cover gasket service will
be performed. Water pump service is described
in Chapter 4.
4. Remove the retaining bolts
gear.
NOTE
Due to the inherent motion of the damper/ring gear hub
in relation to the gear body, the holes to access the
bolts is not likely to align well. You may need to use a
ball hex and a screwdriver to carefully pry through the
holes to align the tool to the fasteners. Take care not to
damage the threads in the crankshaft when doing so.
q
and stator
e
.
3
r
and coupler / starter
3.55