Valve Clearance - Polaris Magnum 2x4 Service Manual

Valve Clearance
Inspect and adjust valve clearance while the engine is cold
and the piston positioned at Top Dead Center (TOC) on
compression stroke.
1 . Lift up on the rear of the seat.
2. Pull the seat back and free of the tabs. NOTE: When
reinstalling seat, make sure the slots in the seat
engage the tabs in the fuel tank.
3. Remove the left and right side body panels and fuel
tank cover. See Body Panel Removal, Chapter 2.
4. Remove the fuel tank.
5. Remove the spark plug high tension lead and remove
the spark plug. CAUTION: Place a clean shop towel
into the spark plug cavity to prevent dirt from entering.
6. Remove the eight 6 x 20 mm bolts securing the rocker
cover. Remove the cover and gasket. NOTE: It may
be necessary to tap the cover lightly with a plastic
hammer to loosen it from the cylinder head.
7. Remove the timing inspection plug from the recoil
housing.
CAUTION: Failure to position the crankshaft exactly as
shown (TOC on compression stroke) will result in improper
valve adjustment.
8. Rotate the engine slowly with the recoil rope, watching
the intake valves open and close.
NOTE: At this point watch the camshaft sprocket marks
and slowly rotate engine until marks are parallel to rocker
cover gasket surface. The cam sprocket locating pin will
be facing upward directly in line with the crankshaft to cam-
shaft center line as shown. See photo at right.
9. Verify accurate TOC positioning by observing the mark
aligned with the line in the timing inspection hole. In
this position there should be clearance on all valves.
Polaris Industries Inc.
2.27
MAINTENANCE
4 Stroke Engine Maintenance
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