Polaris Ranger RZR 800 Manual page 91

14. Inspect the gear teeth and the three tabs on the gears for
wear.
Inspect Teeth & Tabs
Replace 3 Springs
15. Install the new springs into the grooves of the cam gear.
Install Springs
16. Insert the pointed dowels from the Tapered Pins (PU-
45497-1) into the cam gear.
PU-45497-1
To Assemble:
• Hold the spring with one finger.
• Start the pointed end of the tapered pin into the cam
gear hole. Slowly push the dowel through the hole until
the end of the dowel is almost flush with the spring.
• Perform this procedure with all three tapered pins.
• Do not push the pins too far through or the springs will
pop out.
NOTE: Do not remove the tapered pins at this time.
17. Note in photograph that the Tapered Pins (PU-45497-1) are
below flush with end of the springs. This helps to align the
three gear tabs during the next step.
PU-45497-1
Cam Gear Spring Installation Tool Kit:
(PU-45497)
Tapered Pins:
(PU-45497-1)
Cam Gear Tooth Align Tool:
(PU-45497-2)
18. Line up the two gears using the timing marks and the three
gear tabs that were referenced earlier. Push the gears back
together, using both hands and hold securely.
Align Timing Marks
ENGINE
3
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