Polaris 2000 120 XCR Service Manual page 64

15. Install cylinder head to cylinder with new head gasket.
Tighten four flange bolts evenly in three steps by the
following tightening torque:
Cylinder Head
1st step 3.6 ft.lb (5Nm)
2nd Step 7.2 ft.lb (10Nm)
Final Step 17-20 ft.lb. (23-27Nm)
16. Insert push rods into crankcase. Put push rod tip in the
hollow of tappet top.
17. Apply oil to the rocker arms and assemble them to the
cylinder head using pivot bolt and guide plate.
18. Position the piston at top dead center of the compression
stroke. Top dead center may be obtained by placing the key
slot of the power take off shaft to 10 o'clock position.
Top Dead Center
PTO shaft end view
19. Loosen nut under rocker arm and turn the pivot bolt to
adjust the clearance between the rocker arm and valve stem
end. Tighten the lock nut under rocker arm.
= T
ENGINE / CARBURETOR / CLUTCH
Valve Clearance (Intake & Exhaust):
.0031"-.0047" (.08-.12mm)
NOTE: Check and adjust valve clearance while
engine is cold. Check operation of valves by turning
crankshaft. Recheck valve clearance.
20. Install rocker cover and new gasket.
21. Install spark plug in cylinder head.
• NGK BR6ES
Spark Plug 12-14 ft.lbs. (17-19Nm)
22. Insert woodruff key in key way of crankshaft. Wipe off
grease and oil thoroughly from tapered portion of the
crankshaft and flywheel center hole.
Install flywheel to crankshaft. Hold flywheel with strap wrench
to keep from turning. Tighten flywheel nut with starter pulley.
Flywheel Nut 43-47 ft.lb. (59-63Nm)
= In. / mm.
= T
= T
4.25
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