Servicing Top-Side Components - Tracker Off-Road 500S Service Manual

MD1219
NOTE: Support the connecting rod with rubber

bands to avoid damaging the rod or install a connect-
ing rod holder.
CAUTION
Do not allow the connecting rod to go down inside the
crankcase. If the rod is down inside the crankcase and
the crankshaft is rotated, severe damage will result.
AT THIS POINT
To service piston, see Servicing Top-Side Components
sub-section.
AT THIS POINT
To service center crankcase components only, proceed
to Removing Right-Side Components.
Servicing Top-Side
Components
VALVE ASSEMBLY
When servicing valve assembly, inspect valve seats,
valve stems, valve faces, and valve stem ends for pits,
burn marks, or other signs of abnormal wear.
NOTE: Whenever a valve is out of tolerance, it must

be replaced.
Cleaning/Inspecting Cylinder Head
Cover
NOTE: If the cylinder head cover cannot be trued,

the cylinder head assembly must be replaced.
1. Wash the cylinder head cover in parts-cleaning sol-
vent.
2. Place the cylinder head cover on the Surface Plate
covered with #400 grit wet-or-dry sandpaper. Using
light pressure, move the cylinder head cover in a fig-
ure-eight motion. Inspect the sealing surface for any
indication of high spots. A high spot can be noted by
a bright metallic finish. Correct any high spots
before assembly by continuing to move the cylinder
head cover in a figure-eight motion until a uniform
bright metallic finish is attained.
CAUTION
Do not remove an excessive amount of the sealing sur-
face or damage to the camshaft will result. Always
check camshaft clearance when resurfacing the cylin-
der head cover.
CC130D
CAUTION
Water or parts-cleaning solvent must be used in con-
junction with the wet-or-dry sandpaper or damage to the
sealing surface may result.
Removing Valves
NOTE: Index all valves, springs, and cotters to their

original position when removing. When installing, all
valve components should be installed in their original
position.
1. Using a valve spring compressor, compress the valve
springs and remove the valve keepers. Account for
an upper spring retainer.
CC132D
2. Remove the valve seal and the lower remaining
spring seat. Discard the valve seal.
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