2013 600 IQ Racer Service Manual 9923892, Page 74Get this manual
Engine and Cooling Systems DisassemblyAssembly Process 1Remove the coolant from the engine using siphon, wetdry vac, or drain pan2Remove the air box, exhaust pipe and resonator from the engine compartment3Remove the high tension wires and spark plugs from the cylinder head4Remove the thermostat housing outlet cooling hose from the housing5Loosen all, then remove all head cover fastenersClean the fastener threads to remove any thread locking residue6Discard the head cover and cylinder head o-ringsAlways use new o-rings during assembly7Inspect the cylinder headcombustion domes for any damageMeasure cylinder head flatnessReplace cylinder head if required8Loosen all, then remove the cylinder boltsClean the bolt threads to remove any thread locking residue9Carefully pull each cylinder upwards taking care not to drop the piston and rod abruptly against the crankcase10Remove the cylinder base gasketsUse gasket scraper to clean the gasket residue from the crankcase and cylinder bases11Inspect the cylinder wallsNicasil cylinders can only be lightly honedDamage that cannot be removed with light hone requires cylinder replacement or rechroming12The assembly process is the reverse of disassembly13Always use new gaskets and o-rings during assemblyLiberally coat the inside of each cylinder and the outside of each piston with Polaris two-stroke engine oil14When installing piston into cylinder, verify each piston ring opening is located at each piston ring locating pinSqueeze the top ring, then carefully slide the cylinder over the compressed ringDo the same with the bottom ring15Follow the torque specifications and torque sequences located at beginning of chapter when tightening fasteners