How to Remove the Cylinder Head on a Polaris RZR

Removing the cylinder head on a Polaris UTV is a critical part of doing more complex repairs to the engine. 

If you’re rebuilding the engine on your Polaris RZR, you won’t get far without this step. Watch the video above and follow the steps below to learn how to remove a Polaris RZR cylinder head.

Tools Needed – Polaris RZR Cylinder Head Removal

  • 3/8th ratchet
  • 8mm, 14mm sockets
  • 27mm box-end wrench
  • Torx set
  • Soft-blow hammer
  • Telescopic magnet

Polaris RZR 900XP cylinder head

Polaris RZR Cylinder Head Removal

Step 1. Bring the RZR’s motor to top-dead center. 

NOTE: If you’re not sure how to find top dead center, watch our Polaris RZR top end rebuild video below.

Step 2. Remove the four Torx bolts on the valve cover.  

Polaris RZR 900 valve cover

 Step 3. Use a soft-blow hammer to give the valve cover a good tap to knock it loose and remove it. 

Polaris RZR cylinder head removal

Step 4. Use a 27mm wrench to remove the tensioner. 

Polaris RZR cylinder head removal tensioner

Step 5. Remove the two 8mm bolts that hold the camchain guide plate (behind the timing chain sprockets), followed by the plate itself.

Polaris UTV cylinder head removal

Step 6. Remove the two 8mm bolts behind the sprockets to take off the guide holding the front of the cam in place. 

Polaris side-by-side cylinder head removal

Polaris RZR UTV cylinder head removal

Step 7. Remove the four 8mm bolts that hold each of the two cam carriers in place, then take off each carrier. 

Polaris RZR side by side cylinder head removal

Step 8. Lift the cam chain a little to free the sprockets at the end of each cam and then remove the cams. 

Polariz RZR 900 cylinder head removal

Step 9. Use a telescopic magnet to remove the eight tappets. 

Polaris RZR 900XP cylinder head removal

Step 10. Remove the six main bolts with a 14mm socket. They need to be loosened incrementally, rotating among the six bolts. Loosen one of them 1/8th of an inch and then move on to the next and loosen it 1/8th of an inch, moving around the pattern (pictured below) until the bolts are loosened. 

Polaris ZR cylinder head removal bolt sequence

Step 11. Remove the two small 8mm bolts on the side of the head.

Polaris RZR 900XP UTV cylinder head removal

Step 12. Lift the head off and you’re done. 

Polaris 900 side-by-side cylinder head removal

NOTE: You may need to give it a couple of taps from your soft blow hammer to break it free.

Now that your Polaris side-by-side's cylinder head is removed, what next? Watch the video above to learn how to do an engine valve installation on a Polaris RZR 900XP


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