Cylinder Head Removal - Polaris 2004-2005 Sportsman 6x6 Service Manual

GENERAL INFORMATION
3. Measure height of each cam lobe using a
micrometer. Compare to specifications.
Journal O.D.
Camshaft Journal O.D.:
Mag & PTO End: 1.4935-1.4941I
(37.935-37.950 mm)
4. Measure camshaft journal outside diameter
(O.D.)
5. Measure ID of camshaft journal bore.
Camshaft Journal I.D.:
Mag & PTO End: 1.4963-1.4970I
(38.005-38.025 mm)
Calculate oil clearance by subtracting journal OD
from journal bore ID. Compare to specifications.
Camshaft Oil Clearance:
Std: .0022-.0035I (.055-.090 mm)
Limit: .0039I (.10 mm)
NOTE: Replace camshaft if damaged or if any part
is worn past the service limit.
NOTE: Replace cylinder head if camshaft journal
bore is damaged or worn excessively.
Journal

CYLINDER HEAD REMOVAL

1. Remove the two 6mm flange bolts (A) from
cylinder head. See next exploded view on next
page to view item A.
2. Loosen each of the four cylinder head bolts
evenly 1/8 turn each time in a criss-cross pattern
until loose.
3. Remove bolts (B) and tap cylinder head lightly
with a plastic hammer until loose. CAUTION:
Tap only in reinforced areas or on thick parts of
cylinder head casting to avoid damaging the
thread.
4. Remove cylinder head and head gasket.
B
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