Could someone please post the proper torque specs for the cylnder base and the cylnder head nuts. Thanks in advance.

 

I have a Haynes Owners Workshop Manual for Polaris 2 & 4-stroke models from 1985 through 1997 (to cover my '94 400L 4x4...luv it...) and the manual says that for 2-stroke engines the cylinder base bolts are 25 to 29 ft-lbs and the cylinder head bolts are 18 - 20 ft-lbs.

Remember to use the cross-tightening sequence for the head bolts... start with one of the head bolts closest to the 'zero' in the '400' cast into the head (the book shows them starting with the one on the coolant in/out side), then cross over to the opposite bolt by the other zero, then back to the other side again and tighten the bolt closest to the 'four' in '400' the opposite side to the other four in '400' then across the head (parallel to the cooling fins) to the bolt by the zero in '400' and finally across to the last bolt.

I don't know if your '96 is a 2 or 4-stroke. The cylinder head bolt tightening sequence is pretty elaborate for the 4-stroke. If you're talking about a 4-stroke, I send you the tightening information for that.

 

The torque on the cylinder bas bolts is 24ft/lbs per Polaris service manual (no offense to a Haynes manual) I use an extension with a crows foot to get to them. It is kind of hard to do, but it needs to be right or else your asking for a blown gasket. dont forget to give it a warm up and complete cool down and recheck them. The head bolt torque are as per said by Mr leadthumb. Hope this helps,Bubba[img]i/expressions/face-icon-small-happy.gif[/img]

 

thanks guys !