Cylinder Head Removal
NOTE: The cylinder head can be serviced with the
engine installed in the chassis.
1. Remove the two outer M6 bolts
to the cylinder.
2. Loosen the six cylinder head bolts
at a time until all are loose.
3. Remove and discard the cylinder head bolts.
4. Tap cylinder head lightly with a soft faced hammer
5. Tap only in reinforced areas or on thick parts of the
cylinder head casting.
6. Remove the cylinder head and head gasket
Once the cylinder head is removed,
nothing retains the cylinder to the engine. DO
NOT rotate the engine without using the Cylinder
Holding & Camshaft Timing Plate (PU-50563).
Refer to Cylinder / Piston Removal, page 3.56.
9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual
Cylinder Head Warp Inspection
Thoroughly clean cylinder head surface to remove all
traces of gasket material and carbon.
that retain the
Use care not to damage gasket sealing surface. All
gasket surfaces must be clean, dry and free of any oil
or grease upon assembly. Clean sealing surfaces with
rubbing alcohol or electrical contact cleaner. Do not
1. Lay a straight edge
evenly 1/8 turn
© Copyright 2014 Polaris Industries Inc.
ENGINE / COOLING SYSTEM
touch sealing surfaces of the new head gasket.
across the surface of the
cylinder head at several different points and measure
warp by inserting a feeler gauge between the straight
edge and the cylinder head surface. If warp exceeds
the service limit, replace the cylinder head.
Cylinder Head Warp Limit:
0.0039" (0.1 mm)