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Indian motorcycle 2017. Service Manual - page 11

3.57

18. Remove fasteners

and lower camshaft retaining

plate

19. Carefully pull each of the camshafts out from its

respective bore.

NOTE

It may be necessary to rotate the camshaft by hand

during removal so the camshaft lobes can clear the

retaining plate.

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CCAAM

MSSHHAAFFTT IINNSSTTAALLLLAATTIIOONN

1. With the retaining plate and pins installed and the

lifters held in place, install the two exhaust
camshafts

and intake camshaft

NOTE

It may be necessary to rotate the camshaft by hand

during installation so the camshaft lobes can clear

the retaining plate.

2. Assemble the lower camshaft retaining plate

the main plate and tighten fasteners

until the are

hand-tight.

3. Using a suitable wrench, rotate each camshaft

while pulling the respective retaining pin out of the
plate bore to release the lifters.

4. Remove the retaining plate assembly.

5. Install the camshaft carrier, timing components and

ti ming chain cover as outlined in this chapter.

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CCYYLLIINNDDEERR HHEEAADD SSEERRVVIICCEE

VVAALLVVEE CCOOVVEERR RREEM

MOOVVAALL

Remove engine from frame and place on an
engine stand. See Removing Engine From Frame,
page 3.12.

Using a T40 Torx, remove the three fasteners

from each of the outer valve covers and remove
covers.

Using an 8mm socket, remove the fasteners

securing the inner valve covers to the cylinder
head.

Remove inner valve covers and gaskets.

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VVAALLVVEE CCOOVVEERR IINNSSTTAALLLLAATTIIOONN

Using new gaskets, install the inner valve covers
and thread fasteners

in finger tight.

Reference the torque sequence at the beginning of
this section and torque inner valve cover fasteners
to specification.

TORQUE

Inner Valve Cover Fasteners:

89 in-lbs (10 Nm)

Install the outer valve covers and torque fasteners
to specification.

TORQUE

Outer Valve Cover Fasteners:

89 in-lbs (10 Nm)

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CCYYLLIINNDDEERR HHEEAADD RREEM

MOOVVAALL

CAUTION

Cylinder and Cylinder Head heat sink edges are

extremely sharp. Gloves should be worn whenever

handling these components to prevent personal

injury.

Remove engine from frame and place on an
engine stand. See Removing Engine From Frame,
page 3.12.

Remove inner and outer valve covers. See Valve
Cover Removal, page 3.59.

Alternately loosen cylinder head nuts

to relieve

valve spring pressure. Remove nuts and washers.

Remove cylinder heads

and head gaskets

RROOCCKKEERR AARRM

M RREEM

MOOVVAALL

Remove rocker arm fasteners

and remove

rocker arms as an assembly.

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RROOCCKKEERR AARRM

M IINNSSPPEECCTTIIOONN

NOTE

Rocker arms are non-serviceable and must be

replaced as an assembly.

Visually inspect rocker arms and needle bearings
for scoring or damage.

Inspect oil passage

at the push rod cup and

clean thoroughly. Use only clean solvent.

Rotate rocker arm. Rocker arm should move
smoothly without excessive play or binding.
Check for excessive radial movement.

Replace rocker arm assembly if pad or push rod
cup show signs of wear, cracks, nicks or burrs..

CCYYLLIINNDDEERR HHEEAADD DDIISSAASSSSEEM

MBBLLYY

CAUTION

Wear eye protection while removing valve springs.

NOTE

Keep mated parts together for assembly.

Remove the valve keepers

using a valve spring

compressor tool PV-1253. Use a small magnet to
remove valve keepers.

Remove upper valve spring retainers

and

springs

Remove the valves

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3.63

Remove and discard the spring seat / valve stem
seal assemblies

Clean carbon deposits from combustion chamber.

Clean gasket surfaces.

CCYYLLIINNDDEERR HHEEAADD IINNSSPPEECCTTIIOONN

Visually inspect cylinder head for cracks or
damage. Pay close attention to the areas around
spark plug

and valve seats

Inspect cylinder head for distortion with a straight
edge and

feeler gauge.

Check

different

directions and locations on the cylinder head. For
cylinder

head

service

limits,

see

Service

Specifications, page 3.33.

VVAALLVVEE SSPPRRIINNGG FFRREEEE LLEENNGGTTHH IINNSSPPEECCTTIIOONN

Measure free length of valve springs. Replace
springs that do not meet specification. See Service
Specifications, page 3.33.

NOTE

Intake and exhaust springs are identical.

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VVAALLVVEE IINNSSPPEECCTTIIOONN

NOTE

Valve service specifications can be found at the

beginning of this chapter. See Service Specifications,

page 3.33.

Place valves on V-blocks as shown and measure
valve stem runout

using a runout gauge or

similar tool..

Inspect the valve face for damage from burning,
pitting or uneven contact.

Place valves on V-block as shown and inspect
valve head radial runout

Insert valves into their original locations in
cylinder head.

Inspect that each valve moves up and down
smoothly without binding in guide.

Measure valve stem deflection for each valve to
determine

valve

guide

requires

replacement.

A. Raise valve 10mm (0.400") off of seat.

B. Position dial indicator as shown. Measure
deflection in two directions perpendicular to each
other (X & Y axis).

C. If valve deflection exceeds service limit
measure valve stem diameter.

Replace valve and repeat step 6 if valve stem O.D.
measures outside standard range. If valve stem
deflection exceeds service limits with a new valve
installed, valve guide must be replaced.

Installation of new valve guides and/or new valves
requires valve seat reconditioning. This work
should

performed

experienced

technician properly equipped to perform cylinder
head reconditioning.

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3.65

VVAALLVVEE IINNSSPPEECCTTIIOONN

CONDITION

ILLUSTRATION

POSSIBLE CAUSE

CORRECTIVE ACTION

Uneven seat width

Bent valve stem, worn
valve guide

Replace valve and reface
seat

Damaged valve face

Burnt, pitted, foreign
material damage

Replace valve and reface
seat

Contact area too high

Wear, settling of valve seat Lower with 30

stone

Contact area too low

Wear, settling of valve seat Raise with 60

stone

Contact area too wide

Wear, settling of valve seat Narrow with both 30

stone

and 60

stone

Contact area too narrow

Use 45

stone

Contact area free of pitting
and damage, centered in
seat, proper width.

Correct

None

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VVAALLVVEE GGUUIIDDEE RREEM

MOOVVAALL // IINNSSTTAALLLLAATTIIOONN

CAUTION

Replacement of valve guides requires an oven,

special equipment and experience to do the job

correctly. If you are unsure of your ability to do the

repair professionally it is best to sublet the labor to a

competent machinist. Valve seat reconditioning is

required when valve guides are replaced.

Support cylinder head and place valve guide
remover into valve guide from the combustion
chamber side.

Drive or press old valve guides out of cylinder
head.

CAUTION

The cylinder head can be easily damaged if the

procedure is done carelessly.

Apply 90 weight oil to outside of new valve guides.

Drive or press new guides from rocker arm side of
head.

Measure valve guide height from spring seat:

MEASUREMENT

Valve Guide Installed Height:

17.7–18.3 mm

Ream new valve guides to size to obtain specified
stem-to-guide clearance. Ream from combustion
chamber side of head.

Clean

cylinder

head

thoroughly

with

clean

solvent.

Inspect and recondition valve seats.

VVAALLVVEE SSEEAATT IINNSSPPEECCTTIIOONN

NOTE

Valves cannot be ground. If valve face is burned or

badly worn, replace the valve.

Remove carbon deposits from valves and seats.

Inspect valve face for burning, pitting or uneven
contact.

Apply a light coating of machinist’s layout fluid or
paste to valve face.

Install valve into valve guide.

Tap valve several times to make a clear impression
on the valve face. Do not rotate valve.

Remove valve and measure contact area (valve
seat width). See Service Specifications, page 3.33.

If valve seat is incorrect, recondition as needed.

VVAALLVVEE SSEEAATT RREECCOONNDDIITTIIOONNIINNGG

NOTE

Valve seat reconditioning should be performed by a

technician proficient in cylinder head reconditioning

techniques using grinding stones. The use of carbide

cutters is not recommended. Follow

recommendations of the manufacturer of the valve

seat reconditioning equipment being used. Do not

grind seats more than necessary to provide proper

seat width and contact point on valve face.

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CCYYLLIINNDDEERR HHEEAADD AASSSSEEM

MBBLLYY

CAUTION

Wear eye protection during assembly.

Lubricate valve stems with assembly lube.

Install valve in head

before

installing seal. Hold

valve against seat wipe off the portion that extends
above the guide.

Apply Indian Motorcycle engine oil to valve guide
seal and install seal on valve, rotating the seal as
you install it.

Press seal firmly in place on top of guide. Be
careful not to dislodge spring from seal.

Install valve spring and upper retainer.

CAUTION

Do not compress valve springs more than necessary

to install keepers.

Support cylinder head so valves will not be

damaged.

Compress valve springs using a valve spring
compressor and adapter.

Apply a small amount of grease to both sides of a
valve keeper.

Insert both valve keepers in place on valve.

Remove spring compressor.

10. Repeat previous steps for remaining valves.

11. Be sure all keepers are fully seated in groove.

CCYYLLIINNDDEERR HHEEAADD IINNSSTTAALLLLAATTIIOONN

NOTE

The base gasket seal is broken when the cylinder

head is removed and must be replaced. See Cylinder

Installation, page 3.82.

Rocker arms must be removed from cylinder head

prior to installation.

If previously removed, lubricate push rod tube o-
rings with a small amount of engine oil and press
them into the lifter blocks until fully seated.

Verify that locating dowels

are in position on the

cylinder deck.

Thoroughly clean cylinder and cylinder head
mating surfaces.

NOTE

Gaskets and gasket sealing surfaces must be free of

oil and grease during assembly.

Slide push rods through push rod tubes until
seated in lifters.

NOTE

All push rods and rocker arms are identical, although

an effort should be made to put parts back into the

same location from which they were removed.

Install a new head gasket

NOTE

Use care not to damage, tear or displace push rod

tube o-rings when fitting the cylinder head to the

cylinder.

Set cylinder head in place on cylinder and press
down over the push rod tubes until fully seated.

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Apply assembly lube to the tops of the valve
stems.

Install washers and nuts on cylinder studs. Tighten
finger tight.

Fully

torque

cylinder

head

following

the

procedure below to ensure accurate final torque:

Torque

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TTRROOUUBBLLEESSHHOOOOTTIINNGG,, CCYYLLIINNDDEERR HHEEAADD AANNDD VVAALLVVEE TTRRAAIINN

NOTE

Cylinder head, valve train and piston/cylinder problems are usually detected by an engine compression test.

Other problems associated with this area of the engine are external fluid leaks, excessive oil consumption or

abnormal noises.

The troubleshooting tables that follow list

possible

causes of engine mechanical problems. Always thoroughly

investigate before disassembling an engine.

PROBLEM

POSSIBLE CAUSE

PART(S) AFFECTED

REPAIR

RECOMMENDED

Hard Starting / Won’t Start

Low Compression

Worn Valve Guide(s)

Replace Valve Guide(s)

Poor Seating of Valve(s)

Repair or Replace

Broken Valve Spring(s)

Replace

Spark Plug Not Seated

Torque to Specification

Incorrect Valve Timing

Repair / Retest

Valve Stuck Open

Repair / Retest

Cylinder Head Gasket
Leak

Repair / Retest

Slow Starter Motor

Refer to Electrical
chapter

Worn Rings, Piston, or
Cylinder

Refer to Engine / Cooling
/ Exhaust chapter

Collapsed Hydraulic
Lifter(s)

Bleed Air from Lifter(s) /
Run at high idle for 10
minutes

Ignition Problem

Refer to Electrical
chapter

Fuel Problem

Refer to Fuel Delivery /
EFI chapter

Electric Starter Straining
to Turn Engine Over

High Compression

Excessive carbon build-
up in combustion
chamber

De-carbon Combustion
Chamber

Compression Release
Mechanism Failure

Inspect/Repair/Replace
Compression Release
Mechanism

Excessive Starter Load

Internal Engine / Drive
Components Seized or
Binding

Determine Cause of
Seizure or Binding

Poor idle Quality (Engine
Related)

Low Compression

Collapsed Hydraulic
Lifter(s)

Bleed Air from Lifter(s) /
Run at high idle for 10
minutes

Poor Seating of Valve(s)

Repair or Replace

Excessive Oil in
Combustion Chamber

Valve Guides

Replace

Worn Rings, Piston, or
Cylinder

Refer to Engine / Cooling
/ Exhaust chapter

Engine Oil Overfilled

Correct Engine Oil Level

Engine Noise

Valve Train Area

Collapsed Hydraulic
Lifter(s)

Bleed Air from Lifter(s) /
Run at high idle for 10
minutes

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PROBLEM

POSSIBLE CAUSE

PART(S) AFFECTED

REPAIR

RECOMMENDED

Broken or Weak Valve
Spring(s)

Replace

Worn Camshaft or Rocker
Arm

Replace

Rocker Arm Bearing
Damage

Replace

Cam Bearings Worn or
Damaged

Replace

Piston / Cylinder Area

Worn Pistons and / or
Cylinders

Replace

Worn Wrist Pin, Wrist Pin
Bore and / or Connecting
Rod

Replace

Worn Piston Rings or
Piston Ring Lands

Replace

General

Exhaust Leak

Reseal Exhaust

Timing Chain Area

Chain / Sprocket Worn

Replace

Chain Tensioner and / or
Guide Worn

Replace

Bottom End Area

Main Bearings

Refer to Transmission /
Crankshaft chapter

Rod Bearings

Refer to Transmission /
Crankshaft chapter

Loose Side Clearance

Refer to Transmission /
Crankshaft chapter

Transmission Area

Bearings

Refer to Transmission /
Crankshaft chapter

Poor High-Speed Running

Air Intake Problem

Refer to Fuel Delivery /
EFI chapter

Fuel Injection Problem

Refer to Fuel Delivery /
EFI chapter

Ignition Problem

Refer to Electrical
chapter

Valve Float

Weak Valve Springs

Replace

Insufficient Valve Travel

Worn Camshaft / Rocker
Arms

Replace

Valves Opening and
Closing at Wrong Time

Incorrect Valve Timing

Correct

Lack of Power in all RPM
Ranges

Low Compression

Worn Piston, Rings,
Cylinder, Poor Valve
Seating

Repair / Replace

Valve Timing Incorrect

Cam Chain and Sprockets

Correct

Valve Float

Weak Valve Springs

Replace

Insufficient Valve Lift

Worn Camshaft / Rocker
Arms

Replace

Ignition / Fuel Injection
System

—

Refer to Fuel Delivery /
EFI or Electrical chapter

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3.71

PROBLEM

POSSIBLE CAUSE

PART(S) AFFECTED

REPAIR

RECOMMENDED

Oiling Problem

Oil Overfilled

Correct Engine Oil Level

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CCYYLLIINNDDEERR // PPIISSTTOONN

GGEENNEERRAALL IINNFFOORRM

MAATTIIOONN

SSEERRVVIICCEE NNOOTTEESS

NOTE

Clean the machine thoroughly before removing

engine from frame.

• This section covers service of the cylinder, piston

and rings. The engine must be removed from the
frame to perform the procedures in this section.
Refer to Engine / Cooling / Exhaust chapter for
engine removal and installation.

• Mark and store all mated parts for assembly.

Assemble engine by putting used parts that pass
inspection back in the same location.

• Machined mating surfaces are very delicate. Handle

and store all parts in such a way that the mating
surfaces will not be damaged.

• Many parts require assembly lubrication. Follow the

assembly lubrication procedures carefully.

• There are many precision measuring steps in this

section. If you are not sure of your capabilities in
these areas, have a competent machinist perform
the precision part inspection operations.

• Cleanliness of parts is critical to engine life and

proper parts inspection. Use clean solvent and hot,
soapy water to clean parts. Dry with compressed air
before inspection and engine assembly. Coat parts
with fresh lubricant to prevent oxidation after
cleaning.

SSPPEECCIIAALL TTOOOOLLSS

TOOL DESCRIPTION

PART NUMBER

Piston Ring Compressor

PV-43570-A

Clutch Shaft Holding Tool

PF-51232

Cylinder Bore Gauge

PV-3017

Crankshaft Rotation Tool

PF-51239

Crankshaft Locking Pin

PF-52135

Engine Case Splitting Tool

PF-51234

TOOL DESCRIPTION

PART NUMBER

Straightedge, Feeler
Gauge

Commercially
Available

Protective Sleeves For
Pistons / Studs

Commercially
Available

Bosch Automotive Service Solutions:

1-800-328-

6657 or https://polaris.service-solutions.com/

TTOORRQQUUEE SSPPEECCIIFFIICCAATTIIOONNSS

DESCRIPTION

TORQUE

SPECIFICATION

Connecting Rod
Bearing Cap

22 ft-lbs (30 Nm)

Cylinder Studs

25 ft-lbs (34 Nm)

ENGINE / COOLING / EXHAUST

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