5.25
Engine and Cooling Systems
5
Disassembly / Assembly Process - 2008 800 CFI Cylinder
Head / Cylinder / Pistons
1. Remove the coolant from the engine using a siphon, wet/
dry vac, or drain pan.
2. Remove the air box, exhaust pipe and resonator 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 from
the housing.
5. Loosen all, then remove all head cover fasteners. Clean the
fastener threads to remove any thread locking residue.
6. Discard the head cover and cylinder head o-rings. Always
use new o-rings during assembly.
7. Inspect the cylinder head / combustion domes for any
damage. Measure cylinder head flatness. Replace cylinder
head if required.
8. If only the cylinder is going to be removed, remove the fuel
rail from the upper fuel injectors. See “CFI Fuel Rail/
Injector(s) Removal/Installation” on page 4.30.
9. Loosen all, then remove the cylinder bolts. Clean the bolt
threads to remove any thread locking residue.
10. Carefully pull the cylinder upwards taking care not to drop
the pistons and rods abruptly against the crankcase.
11. Remove the cylinder base gasket. Use a gasket scraper to
clean the gasket residue from the crankcase and cylinder
base.
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. Inspect the crankcase and cylinder mating surfaces for
warping.
14. The assembly process is the reverse of disassembly.
15. Always use new gaskets and o-rings during assembly.
Liberally coat the inside of each cylinder bore and the
outside of each piston with Polaris two-stroke engine oil.
16. When installing a piston into a cylinder, verify each piston
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 specifications and torque sequences
located at beginning of chapter when tightening fasteners.
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