Camshaft Inspection; Cylinder Head Removal - Polaris Outlaw 500 Service Manual

ENGINE

Camshaft Inspection

1. Visually inspect each cam lobe for wear, chafing or
damage.
NOTE: Camshafts, gears and bearings are not
serviceable. Replace camshaft as an assembly if
problems are found.
2. Inspect the cam bearings for excess play or noise during
rotation.
3. Measure height of each cam lobe using a micrometer.
Compare to specifications.
Camshaft Lobe Height
Limit: 1.6555ð (42.05 mm)
4. Measure camshaft journal outside diameter (O.D.)
Check for wear
or roughness
Camshaft Journal O.D.:
Mag End: .9821- .9828ð
(24.946- 24.963 mm)
3.16
5.
NOTE:
damaged or if any part is worn past the service limit.
6.
NOTE: Replace cylinder head if camshaft journal
bore is damaged or worn excessively.

Cylinder Head Removal

1.
2.
3.
Journal O.D.
4.
5.
Measure ID of camshaft journal bore.
Camshaft Journal I.D.:
Mag End: .9842- .9851ð
(25.00- 25.021 mm)
Replace camshaft as an assembly if
Calculate oil clearance by subtracting journal OD from
journal bore ID. Compare to specifications.
Camshaft Oil Clearance
Limit: .0039ð (.10 mm)
Remove the cam shafts.
Remove the two 8mm flange bolts (A) from cylinder head.
Loosen each of the four cylinder head bolts (B) with a
14mm 12-point socket, turning evenly 1/8 turn each time
in a criss–cross pattern until loose.
A
Remove bolts (B) and tap cylinder head lightly with a soft-
face hammer until loose.
CAUTION
Tap only in reinforced areas or on thick parts of
cylinder head casting to avoid
damaging the head.
Remove cylinder head and head gasket.
B
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