2005 Polaris Sportsman 400/500 Service Manual, Page 105Get this manual
ENGINE 9Tighten the cylinder bolts in three steps in criss cross pattern and torque to specifications10Install the two mm boltsCylinder Bolt Torque: 10mm46 ftlbs(62 Nm) 6mmftlbs(8 Nm) Guide in recess
CYLINDER HEAD INSTALLATION
Clean the gasket surfaces on the cylinder head and cylinderRemove all traces of old gasket materialRefer to disassembly photos1Install the cam chain tensioner guideBe sure bottom end of guide is located properly in crankcase2Install the two dowel pins and new cylinder head gasket3Place the cylinder head on the cylinderApply film of engine oil to the cylinder head bolt threads and washers, and hand tighten the boltsThe following procedure must be used to torque the cylinder head properly: Torque all bolts evenly in criss cross pattern Torque bolts to 22 ftlbs(30 Nm) Torque bolts to 51 ftlbs(70 Nm) Loosen bolts evenly 180 (12 turn) Loosen bolts again another 180 (12 turn) Torque bolts to 11 ftlbs(15 Nm) From this point, tighten bolts evenly 90 (14 turn) Finally, tighten another 90 (14 turn) Install two 6mm bolts and torque to ftlbs(8 Nm)