Cylinder Head Installation - Polaris 1999 Sportsman 400 Service Manual

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CHAPTER FOUR
der head at severa l locations (F igure 73). Compare
the reading with the warp limit listed in Table 4.
8. Inspect the camshaft bearing surfaces (Figure 74)
in the cylinder head for wear or scoring. Also check
the oil delivery port (Figure 75) for blockage.
9. Remo ve the oil pressure blind plug (Figure 76)
in
front
of the oil delivery port
10
assist with clean-
ing. Coat the threads of the blind plug with sealer
before installing. then tighten
securely.
10. Inspect the mounting bolts for thread damage
and stretching (Figure 77). Replace as a set if any
are damaged.
Ins ta llation
I.
If removed, install the two locating dowels (A,
Figure 78) in the cylinder block.
2. Position the new gasket (B, Figure 78) onto the
cylinder block and over the locating dowels. Make
sure all coo lant and bolt holes are aligned correctly.
3. Position the cylinder head over the dowels in the
cylinder block and push it down until it completely
seats.
4. Usc a piece of wire to pull the cam shaft chain lip
through the top of the cylinder block chain cavity.
Pull up on the cams haft chain and make sure
it
is
properly meshed with the crankshaft drive sprocke\.
Secure the chain to the exterior of the engine (A,
Figure 79).
5. Apply engine oil to the four large mounting bolts
and two smaller bolt threads. Also apply oil to both
sides of the large washers (Figure 80).
6. Install the small bolts (B, Figure 79) and tighten
finger-tight.
7. Install the four large bolts and washers (F igure
81) and tighten finger-tigh t.
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