Polaris 2004-2005 Sportsman 6x6 Service Manual page 85

GENERAL INFORMATION
EXHAUST VALVE
CLEARANCE ADJUSTMENT
Feeler Gauge for Both Valves
NOTE: The exhaust valves share a common rocker
arm, and must be adjusted using two feeler gauges.
1. Insert .006 feeler gauge(s) between end of
exhaust valve stem and adjuster screw(s).
2. Loosen locknut(s) and turn adjuster screw(s) until
there is a slight drag on feeler gauge(s). The
Valve/Clutch Adjuster Tool (PA- -44689) can be
used to adjust the 500 engine valves. NOTE:
Both feeler gauges should remain inserted during
adjustment of each valve.
EXHAUST VALVE CLEARANCE
.006" (.15 mm)
3. When clearance is correct, hold adjuster screw
and tighten locknut securely
4. Re-check the valve clearance.
5. Repeat adjustment procedure if necessary until
clearance is correct with locknut secured.
CYLINDER/PISTON REMOVAL
AND INSPECTION
NOTE:
500 Engine
remove valve cover, camshaft and rocker arms, and
cylinder head.
1. Remove cam chain guide at front of cylinder.
2. Loosen all four oil pipe banjo bolts and then
Follow engine disassembly procedures to
remove the bolts and eight sealing washers.
Remove the pipes.
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