Engine Assembly; Precautions For Reassembly; Engine Reassembly - Polaris 2000 120 XCR Service Manual

ENGINE / CARBURETOR / CLUTCH
27. Remove clips (18) and piston pin (19).
28. Remove piston from connecting rod.
29. Remove piston rings (20) from piston.
20
19
17
16
30. Remove crankshaft by tapping the flywheel end with a
rubber mallet.
31. Loosen the cam lock nut and remove pivot bolt (21).
32. Remove rocker arms (22).
CAUTION
Wear eye protection to prevent injury.
33. Press down spring retainer (23), take out valve collets (24),
then remove spring retainer and valve spring (25).
21
23
24
34. Remove intake and exhaust valves.
4.22
18
15
22

ENGINE ASSEMBLY

Engine Assembly Torques
Item
Connecting Rod Cab Bolt
Crankcase Bolt Torque
Cylinder Head (Step 1)
Cylinder Head (Step 2)
Cylinder Head (StepFinal)
Spark Plug
Flywheel Nut
Ignition Coil Fasteners

PRECAUTIONS FOR REASSEMBLY

1. Clean parts thoroughly before reassembly. Pay attention
to cleanliness of piston, cylinder, crankshaft, connecting
rod, and bearings.
2. Scrape off all carbon deposits from cylinder head, piston
top and piston ring grooves.
3. Replace oil seal. Apply oil to the lip before reassembly.
4. Replace all the gaskets with new ones.
5. Replace keys, pins, bolts, nuts, etc., if necessary.
6. Torque bolts and nuts to specification.
7. Apply oil to rotating and sliding portions.
8. Check and adjust clearances and end plays where specified
in this manual.

ENGINE REASSEMBLY

1. Install crankshaft in crankcase wrapping the shaft with
vinyl electrical tape to avoid damage to oil seal.
2
1
2. Install woodruff key for the flywheel on crankshaft.
3. Oil tappets and install them in their original position. Push
in fully to avoid damage during installation of camshaft.
ft.lb Nm
6.5-8.3 8.8-11.2
6-7 8-9.5
3.6 5
7.2 10
17-20 23-27
12-14 16.6-19.3
43-47 59-63
6.5-8 8.8-11