Cylinder Head Inspection; Cylinder Head Warp; Valve Seal/Spring Service; (On Engine) - Polaris 2007 SPORTSMAN X2 800 Service Manual

Cylinder Head Inspection

Thoroughly clean cylinder head surface to remove all traces of
gasket material and carbon.
CAUTION
Use care not to damage sealing surface.

Cylinder Head Warp

1. Lay a straight edge (A) across the surface of the cylinder
head (B) at several different points and measure warp by
inserting a feeler gauge between the straight edge and the
cylinder head surface. If warp exceeds the service limit,
replace the cylinder head.
A
Measure at different
points on the surface.
Cylinder Head Warp Limit:
.004" (.1016 mm) max
B
= In. / mm.

Valve Seal/Spring Service

(On Engine)

NOTE: The following procedure is only for servicing
the top end of the valve train when replacing valve
springs or replacing valve seals.
In some cases the valve train can be serviced while the cylinder
head is still on the engine. Keep all parts in order with respect
to their location in the cylinder head.
WARNING
Wear eye protection or a face shield during cylinder
head disassembly and reassembly.
1. Having already removed the valve cover, rocker arms and
pushrods, align the cylinder to be worked on at top dead
center (TDC). Install the Valve Pressure Hose (PU-
45652) into the spark plug hole. Hook the hose to an air
compressor and supply 50 to 100 psi to the hose. This will
seat the valves during valve spring removal. Do not
remove air from the hose at anytime until reassembly is
completed.
2. Using the Valve Spring Compressor (PU-45257),
compress the valve spring and remove the valve keepers.
NOTE: A small parts magnet (A) can aid in the removal
of the retainers (B).
PU-45257
NOTE: To prevent damage to the valve seals, do not
compress the valve spring more than is needed to
remove the valve keepers.
3. Remove spring retainer and spring.
4. The valve seals are now serviceable.
ENGINE
B
A
3.23
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