Cylinder Installation; Cylinder Head And Camshaft Installation - Polaris Hawkeye Repair Manual

ENGINE

CYLINDER INSTALLATION

NOTE: Clean the gasket surfaces on the crankcase and
cylinder. Remove all traces of old gasket material or
sealant. The surfaces must be oil-free!
1. Apply a small amount of crankcase sealant at the case
parting lines (A). Do not allow sealant to dry.
Assemble the top end immediately.
A
Install the dowel pin(s).
2.
3. Install a new base gasket onto the mating surface and
position the Piston Support Block (PN 2870390)
beneath the piston skirt to support the piston during
cylinder installation.
4. Apply clean engine oil liberally to the bore and tapered
area of the cylinder. Place the cylinder on to the studs.
NOTE: Route cam chain through the cylinder chain room
and secure it, holding it up to avoid damage to the chain,
drive sprocket teeth or tensioner blade.
5. Loop the cam chain through the cylinder chain room
and secure with mechanic's wire.
Install cylinder carefully with a front to back rocking
6.
motion until rings are fully captive in the sleeve, then
remove the compressor and support block.
7. Seat the cylinder firmly onto the base gasket.
3.40
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Install the cam chain guide and dowel pins into the
8.
cylinder. Verify the bottom end of the guide is seated
properly in the crankcase.
CYLINDER HEAD AND CAMSHAFT
INSTALLATION
NOTE: Clean the gasket surfaces on the cylinder head
and cylinder. Remove all traces of old gasket material.
The surfaces must be oil-free!
1. Install the dowel pin(s) and a new cylinder head
gasket.
2. Pull the cam chain through the cylinder head chain
room and secure with mechanic's wire.
3. Place the cylinder head on the cylinder.
4. Install the two 6 mm bolts on cylinder base and on the
head, but do not tighten.