Cylinder Head Installation - Polaris 2009 Sportsman XP 850 Service Manual

Cylinder Head Installation

1. Prepare cylinder head gasket sealing surfaces by cleaning
thoroughly to remove all residue. The head gasket must be
installed clean and dry, free from oil or grease.
NOTE: Do not touch sealing surfaces of gasket.
2. Reinstall (2) head alignment pins in upper crankcase.
3. Install cam chain tensioner blade in upper crankcase. Install
a new O-ring on pivot bolt and lubricate with engine oil.
Torque bolt (A) to specification.
90 lb-in.
(10 Nm)
A
4. Lift cam chain and install chain guide.
5. Be sure tabs (B) are engaged in slots. Secure cam chain with
a wire so it will not fall into crankcase.
B
6. Thread cam chain through a new head gasket and install
gasket, locating it on the alignment pins.
7. Set cylinder head in place on alignment pins. Apply engine
oil to threads and flange of the (6) main cylinder head bolts.
8. Tighten main head bolts finger tight, then install the two
6mm outer bolts.
CYLINDER HEAD TORQUE PROCEDURE
• Tighten (6) main head bolts snug.
• Torque (6) main head bolts in sequence shown below to
43.5 lb-ft. (59 Nm).
• Tighten each main head bolt an additional 90 degrees
(1/4 turn) following torque sequence.
• Install (2) M6 outer head bolts (C) and torque to
specification.
ENGINE
5
C
5.35