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Polaris XP Turbo/S & Pro XP & Turbo R 11mm Head Stud Kit — Install Guide

Polaris · Pro XP (RZR) · SKU 800FP0001 (ARP2000), 800FP0017 (CA625)

What's in the Box

Included parts
11mm Nuts Qty 6
11mm Washers Qty 6
11mm Studs Qty 6
Assembly Lube Qty 1
6mm Head Studs Qty 2
Required tools
Torque Wrench (ft-lb)
Metric Socket Set
Flat Head Screwdriver
Torx Set

Installation

1
Pinch off all coolant lines going to the engine and valve cover. Remove the coolant reservoir cap if you haven’t done that already. Once all coolant lines are pinched off remove the valve cover coolant line. NOTE: there may be pressure behind this hose, cap the barb off with a silicone cap.
2
Disconnect the spark plug coil packs and loosen the coil packs with a 8mm socket. Pull the coil packs out of the valve cover.
3
Remove the (4) valve cover screws using a T-40 torxs. Keep the rubber gromets. Remove the valve cover and gasket.
Polaris Pro XP (RZR) installation
4
Remove the crankcase position sensor using an 8mm socket. Find TDC and slide the cam locking tool into place. Tool Number: PU-50563-1. To double check TDC you can find a (+) sign looking through the crankcase position sensor port.
5
Remove the cam chain tensioner using a M6 Allen. Check gasket for any tears.
6
Remove the (2) retaining bolts holding the top guide in place, using a 8mm socket.
Polaris Pro XP (RZR) installation
7
Clean the cam sprockets and chain. With a sharpie make (2) marks on each gear and chain for installation purposes.
8
Place a 22mm wrench on the intake cam, spin the clutch to release pressure off the valves while loosening the intake cam sprocket. Remove the sprocket once hardware is removed.
9
Loosen both camshaft carriers using a 8mm socket. Remove carriers and cam shafts from the engine. Zip tie the cam chain up to the bed mount so the chain doesn’t come off the crank.
Polaris Pro XP (RZR) installation
10
Remove one head bolt and replace it with a stud at a time so the cylinder head never has more than one bolt/stud loose at a time. Lather both ends of the stud with supplied ARP assembly lube. Hand tighten the stud until it bottoms out. Place assembly lube on both sides of the washer, place the washer on the stud. Finger tighten the nut onto the stud and torque to 50 ft/lbs. See torque sequence and specifications below.
1
50 ft/lb 50 ft/lb.
2
68 ft/lb 72 ft/lb.
Polaris Pro XP (RZR) installation
3
85 ft/lb 95 ft/lb.
1
10 ft/lb 10 ft/lb.
11
Reinstall the camshafts and camshaft carriers. Snug up the camshaft carriers. Install cam shaft timing plate back into the camshafts. Verify TDC mark on the flywheel making sure the engine is still timed. Install the intake sprocket back onto the intake camshaft. Make sure your sharpie marks align properly. Apply red Loctite to the sprocket hardware and torque camshaft sprocket to 14 ft/lb. Reinstall the outer camshaft carrier and chain guide. Torque all camshaft carrier bolts to 7 ft/lb.
Polaris Pro XP (RZR) installation
12
Remove the spring retainer bolt out of the spring tensioner and push the adjuster all the way in. Install the cam chain tensioner into the block and torque the mounting bolts to 7 ft/lb. Install the tensioner spring, washer and retainer bolt. Torque spring tensioner bolt to 12 ft/lb.
13
Rotate the crankshaft two full revolutions to verify camshaft timing.
14
Reinstall the valve cover gasket, place a silicone based liquid gasket around the two lobes before installing. Place the valve cover over the camshafts and torque (4) valve cover screws to 7 ft/lb.
Polaris Pro XP (RZR) installation
Polaris Pro XP (RZR) installation
Polaris Pro XP (RZR) installation

Note: This product is exempt from the emission standards and related requirements of 40 C.F.R. § 1051 as provided by 40 C.F.R. § 1051.620, and California law [e.g., vehicle code§§ 27156 and 38391]. This product is sold only for use in connection with EPA certified, purpose-built, nonroad vehicles used solely for closed course, nonroad competition/racing and not used for any recreational purpose or on public highways or right of ways maintained by and open to the public. This product is sold only in connection with machines that do not fall under state and/or federal noise or emission standards/regulations. Purchasers who/that purchase this product represent and warrant that the product is purchased only in connection with EPA -certified, emission-regulations-exempt and noise- regulations-exempt competition/racing vehicles as interpreted under applicable state and/or federal law. Questions: Call Evolution Powersports at (715) 247-3862.