Top End - Polaris Sportsman 700 Efi 2005 Service Manual

ENGINE EXPLODED VIEW

TOP END

1
Lubricate threads and be-
tween washers and underside
of bolt heads with engine oil
Torque in sequence provided.
Apply Moly Lube
2
grease to valve tips.
Gasket free of oil. Verify
3
are visible.
tabs
Apply thin film of 0W--40 to
4
25--55 mm of cylinder bore.
5
Apply 0W--40 to piston
pin or pin bore.
6
Apply 0W--40 to lifters.
Do not install expansion plug
more than 1.5 mm inward.
1.5 mm
Side View
Apply Polaris 0W--40 oil.
Apply Moly
ML
Lube Grease.
Head Bolts
(Each Bolt
Threads)
2
ML
Bushing
Expansion
Plug
5
3
Gasket
1
Initial: 15 2 ft. lbs. (20.3
±
to seat gasket and back off 5 turns
Re--torque to 35 4 ft. lbs (47.5
±
5.5 Nm). Finalize sequence by tight-
ening an additional
3 1
6 2
Head Bolt Tighten Sequence
Rocker Arms
3 Gasket
Pushrods
ML
4
Cylinder
Piston Assembly
Circlip UP for Install
Hydraulic Lifter
ENGINE
2.7 Nm)
±
±
90° (1/4 turn)
5
4
22 2 ft. lbs.
±
(30 3 Nm)
±
0
3.5