Valve Inspection - Polaris SPORTSMAN 600 2003 Service Manual

VALVE INSPECTION

1. Remove all carbon from valves with a soft wire
wheel or brush.
2. Check valve face for runout, pitting, and burnt
spots. To check for bent valve stems, mount
valve in a drill or use "V" blocks and a dial
indicator.
3. Check end of valve stem for flaring, pitting, wear
or damage (A).
4. Inspect split keeper groove for wear or flaring of
the keeper seat area (B). NOTE: The valves can
be re-faced or end ground, if necessary. They
must be replaced if extensively worn, burnt, bent,
or damaged.
5. Measure diameter of valve stem with a
micrometer in three places, then rotate 90
degrees and measure again (six measurements
total). Compare to specifications.
3.22
6. Measure valve guide inside diameter at the top
middle and end of the guide using a small hole
gauge and a micrometer.
directions.
A
B
0.2374"
7. Subtract valve stem measurement from the valve
guide measurement to obtain stem to guide
clearance. NOTE: The valve guides cannot be
replaced. Be sure to measure each guide and
valve combination individually.
Valve Stem Diameter:
Intake: 0.2356" 0.00039"
(5.985 0.01 mm)
Exhaust: 0.2346"
(5.96 0.01 mm)
Measure valve stem in several places.
Rotate the valve 90 degrees and mea-
sure for wear.
Valve Guide
Valve Guide I.D.:
0.00059" (6.030
ENGINE ENGINE
0.00039"
Measure in two
0.015 mm)