Cylinder Head Reassembly - Polaris SPORTSMAN 600 2003 Service Manual

ENGINE ENGINE
VALVE SEAT RECONDITIONING CONT"D
8. Clean all filings from the area with hot soapy
water, rinse, and dry with compressed air.
WARNING
Wear eye protection or a face shield when
working with compressed air during cylinder
head disassembly and reassembly.
9. Lubricate the valve guides with clean engine oil,
and apply oil or water based lapping compound to
the face of the valve. NOTE: Lapping is not
required with an interference angle valve job.
10. Insert the valve into its respective guide and lap
using a lapping tool or a section of fuel line
connected to the valve stem.
11. Rotate the valve rapidly back and forth until the
cut sounds smooth. Lift the valve slightly off of the
seat, rotate 1/4 turn, and repeat the lapping
process. Do this four to five times until the valve is
fully seated, and repeat process for the other
valve(s).
12. Thoroughly clean cylinder head and valves.
CYLINDER HEAD
REASSEMBLY
NOTE: Assemble the valves one at a time to maintain
proper order.
1. Apply engine oil to valve guides and seats.
2. Install new valve seals on valve guides.
3. Coat valve stem with molybdenum disulfide
grease or 0W--40 Synthetic oil.
4. Install valve carefully with a rotating motion to
avoid damaging valve seal.
5. Dip valve spring and retainer in clean engine oil
and install.
6. Place retainer on spring and install Valve Spring
Compressor (PU- -45257). Install split keepers
with the gap even on both sides. NOTE: A small
parts magnet can aid in installation of the
keepers.
(PU- -45257)
7. Repeat procedure for remaining valves. When all
valves are installed, tap lightly with soft faced
hammer on the end of the valves to seat the split
keepers. NOTE: To prevent damage to the valve
seals, do not compress the valve spring more
than necessary to install the keepers.
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