I recently aquired a 2003 Sportsman 700 that is leaking coolant into the crankcase. Weep hole is dry, engine runs great. I feel it's either the head or base gasket that has let go on it. I've seen on here that the head bolt torque is 35 plus a quarter turn, but I have a Polaris Service Manual (p/n 9918066) that shows 60-64 for the torque value. What is the most up to date data? I will be using OEM gaskets.

Thanks

 

I'm not sure but it's probably one of those heads that has to be re-torqued in a specific pattern a couple of times at different values. OPT should come to the rescue after he gets some sleep.

 

I'd go by the latest one. 2003 showed something like 64 ft pounds if I remember correctly,but that changed.The 2005 showed 15 ft pounds initially,back off 5 turns,retorque to 35 ft pounds,then a final 90 degrees(1/4 turn) The last year showed this which I'd go by.

Lubricate threads between washer and underside of bolt with engine oil.
Torque in sequence to spec provided(35 ft pounds) allow the gasket to set for 1 minute, then
tighten in sequence 90 degrees (1/4 turn)

 

Thank you for your help!

 

Good Morning, just out of curiousity, are the head bolts single use, or can they be reused?

Thanks,

 

Back off 5 turns loosing it up the and re torgue ?