Cylinder/Piston Removal And Inspection - Polaris 2007 Sportsman 500 EF Service Manual

Cylinder/Piston Removal and Inspection

NOTE: Follow engine disassembly procedures to
remove valve cover, camshaft and rocker arms, and
cylinder head.
1. Remove cam chain guide at front of cylinder.
2. Loosen all four oil pipe banjo bolts and then remove the
bolts and eight sealing washers. Remove the pipes.
3. Loosen hose clamps and remove coolant inlet hose.
4. Remove the two 6 mm cylinder base bolts.
5. Loosen each of the four large cylinder base bolts 1/4 turn
at a time in a criss-cross pattern until loose and remove
bolts.
NOTE: The bolts are inside the water jacket.
6. Tap cylinder lightly with a plastic hammer in the reinforced
areas only until loose.
7. Rock cylinder forward and backward and lift it from the
crankcase, supporting piston and connecting rod. Support
piston with Piston Support Block (PN 2870390).
8. Remove dowel pins from crankcase.
ENGINE
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