Thermostat Installation; Oil Pipes - Polaris Sportsman 400 Service Manual

ROCKER SHAFT/ROCKER ARM ASSEMBLY INSTALLATION
1. Assemble rocker arms, rocker shaft, and shaft supports.
2. Install and tighten rocker arm shaft locating bolt.
3. Apply starter drive grease to the cam lobes and cam follower surfaces.
4. Rotate the engine until the cam lobes are pointing downward.
5. Be sure the dowel pins are in place and install the rocker shaft assembly.
6. Apply a light film of engine oil to the threads of the bolts and tighten evenly.
Rocker Shaft Support Tower Bolt Torque:
9 ft. lbs. (1.242 kg-m)
Rocker Shaft Locating Bolt Torque:
6 ft. lbs. (.828 kg-m)
7. Adjust valves according to the valve adjustment procedure found in Chapter 2, Maintenance.
8. Apply clean engine oil liberally to the valve springs, cam chain, rocker arms, and camshaft.
9. Place a new rocker cover gasket on the cylinder head and install the cover and bolts.
Rocker Cover Bolt Torque:
6 ft. lbs. (.828 kg-m)

THERMOSTAT INSTALLATION

Install the thermostat with one of the air bleed holes
positioned next to the upper thermostat cover bolt hole
as shown.

OIL PIPES

Install the oil pipes with new sealing washers. Tighten
all bolts evenly to specified torque.
Oil Pipe Bolt Torque:
20 ft. lbs. (2.76 kg-m)
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