Can anyone supply me with torque values and sequence for replacing cylinder and head bolts on Sportsman 500?
Thanks

 

This is straight from the factory manual for 2005 and 2006 450 and 500 Sportsman.

CYLINDER INSTALLATION:

Assuming you've installed the piston and cylinder base gasket, steps 1 thru 6 can be skipped.

7. Apply a light film of oil to the threads and flange surface of the cylinder mounting bolts.

8. Install all four bolts finger tight. Rotate the engine and position the piston at BDC.

NOTE: If cam chain is installed, hold it up while rotating the engine to avoid damage to the chain, drive sprocket teeth, or tensioner blade.

9. Tighten the cylinder bolts in three steps in a criss cross pattern and torque to specifications.

10. Install the two 6mm bolts.

CYLINDER BOLT TORQUE: 10mm - 46 ft. lbs. (62 Nm), 6mm - 6 ft. lbs. (8 Nm)

CYLINDER HEAD INSTALLATION:

Clean the gasket surfaces on the cylinder head and cylinder. Remove all traces of old gasket material. Refer to disassembly photos.

1. Install the cam chain tensioner guide. Be sure bottom end of guide is located properly in crankcase.

2. Install the two dowl pins and a new cylinder head gasket.

3. Place the cylinder head on the cylinder. Apply a film of engine oil to the cylinder head bolt threads and washers, and hand tighten the bolts.

The following procedure must be used to torque the cylinder head properly:

Torque all bolts evenly in a criss cross pattern.

* Torque bolts to 22 ft. lbs. (30 Nm)
* Torque bolts to 51 ft. lbs. (70 Nm)
* Loosen bolts evenly 180 degrees (1/2 turn)
* Loosen bolts again another 180 degrees (1/2 turn)
* Torque bolts to 11 ft. lbs. (15 Nm)
* From this point, tighten bolts evenly 90 degrees (1/4 turn)
* Finally, tighten another 90 degrees (1/4 turn)
* Install two 6mm bolts and torque to 6 ft. lbs. (8 Nm)

Hope this helps.

 

Thanks for the information. A lot more to it than I thought.