Cylinder Head Warp Inspection - Polaris RZR PRO R Service Manual

ENGINE / COOLING SYSTEM

CYLINDER HEAD WARP INSPECTION

Thoroughly clean cylinder head surface to remove all
traces of gasket material and carbon.
Use care not to damage gasket sealing surface. All
gasket surfaces must be clean, dry and free of any oil
or grease upon assembly. Clean sealing surfaces with
rubbing alcohol or electrical contact cleaner. Do not
touch sealing surfaces of the new head gasket.
Lay a straight edge across the surface of the cylinder
q
head 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.
MEASUREMENT
Cylinder Head Warp Limit:
.0039" (0.1 mm)
1. Clean the cylinder head bolts.
IMPORTANT
Do not use a wire brush on any gasket sealing surface.
2. Clean the cylinder head. Remove all varnish, soot
and carbon to the bare metal.
3. Clean the valve guides.
4. Clean the threaded holes. Use a nylon bristle brush.
5. Clean the remains of the sealer from the plug holes.
6. Inspect the cylinder head bolts for damaged threads
or stretching and damaged heads caused by
improper use of tools.
7. Replace all suspect bolts.
3.48
CAUTION
8. Inspect the cylinder head for cracks. Check between
the valve seats and in the exhaust ports.
IMPORTANT
Do not attempt to weld the cylinder head, replace it.
9. Inspect the cylinder head deck for corrosion, sand
inclusions and blow holes.
10. Inspect the cylinder head deck surface for flatness.
Surface Head Flatness
Longitudinal or Transverse: 0.0012 in (0.03 mm)
Overall: 0.0035 in (0.09 mm)
IMPORTANT
If the cylinder head is out of specification, replace the
cylinder head. Do not machine the cylinder head.
11. Inspect the sealing surfaces.
9940259 R02 - 2022 RZR PRO R / PRO R 4 Service Manual
© Copyright Polaris Industries Inc.