3.23
Engine/Cooling/Exhaust
3
Disassembly / Assembly Process
1. Remove the coolant from the engine using a siphon,
wet/dr
y vac, or drain pan.
2. Remove the oil tan
k/clutch cover, air box assembly,
and exhaust pipe from the engine compartment.
3. Remove the high tension wires and spark plugs from
the
cylinder head.
4. Remove the thermostat housing outlet cooling hose
fro
m the housing.
5. Loosen all, then remove all head cover fasteners.
Clea
n the fastener threads to remove any thread
locking residue.
6. Discard the head cover and cylinder head o-rings.
Always us
e new o-rings during assembly.
7. Inspect the cylinder head / combustion domes for any
da
mage. Measure cylinder head flatness. Replace
cylinder head if required.
8. If only the cylinder(s) are going to be removed,
r
emove the fuel rail from the upper fuel injectors.
9. Loosen all, then remove the cylinder base nuts.
10. Carefully pull each cylinder upwards taking care not
to dr
op the piston and rod abruptly against the
crankcase.
11. Remove the cylinder base gaskets. Use a gasket
scrap
er to clean the gasket residue from the
crankcase and cylinder bases.
12. Inspect the cylinder walls. Nicasil cylinders can only
be
lightly honed. Damage that cannot be removed
with a light hone requires cylinder replacement or re-
chroming.
13. The assembly process is the reverse of disassembly.
14. Always use new gaskets and o-rings during
assem
bly. Liberally coat the inside of each cylinder
and the outside of each piston with Polaris two-stroke
engine oil.
15. Always refresh the cylinder crosshatch pattern using
a
320 grit stone. See “Cylinder Honing” on page 3.14.
16. When installing a piston into a cylinder, verify each
pi
ston ring opening is located at each piston ring
locating pin. Squeeze the top ring, then carefully slide
the cylinder over the compressed ring. Do the same
with the bottom ring.
17. Follow the torque spe
cifications and torque
sequences located at beginning of chapter when
tightening fasteners.
To Next Page
Loading...
Need help?
General
