Cam Chain Tensioner Installation - Polaris Sportsman 400 Service Manual

CAM CHAIN TENSIONER INSTALLATION

1. Release the ratchet pawl (A) and push the
tensioner plunger (B) all the way into the
tensioner body.
2. Install the tensioner body with a new gasket and
tighten the bolts.
Tensioner Bolt Torque:
6 ft. lbs. (.828 kg-m)
3. Install the spring, new sealing washer, and
tensioner plug.
Tensioner Plug Torque:
17 ft. lbs. (2.346 kg-m)
4. Slowly rotate engine two to three revolutions and
re-check cam timing.
STATOR, FLYWHEEL AND STARTER DRIVE INSTALLATION
NOTE: The stator, flywheel, starter drive, and recoil
can be assembled with the engine in the frame.
Stator
1. Apply a light film of grease to the crankshaft seal.
Apply molybdenum disulfide grease or assembly
lubricant to the crankshaft bushing.
2. Install a new O-Ring in the oil passage recess in
the crankcase.
3. Apply 3 Bond 1215 (P/N 2871557) or an
equivalent sealer to the stator plate outer surface
and install a new O-Ring.
4. Install the stator plate being careful not to damage
the seal. Align timing reference marks on the plate
and crankcase. Be sure the plate is fully seated.
NOTE: This is a static timing mark. Strobe timing
should be performed after start up.
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ENGINE
B
A
3.71