Polaris TRAIL BOSS 325 2001 Manual page 68

ENGINE
ENGINE REMOVAL
REFER TO PAGE 3.5 - 3.6 FOR ENGINE REMOVAL / INSTALLATION NOTES.
CAM CHAIN TENSIONER REMOVAL
1. Remove ignition timing inspection plug from recoil housing.
To position crankshaft at Top Dead Center
(TDC) on compression stroke:
2. Rotate engine slowly in the direction of rotation
watching intake valves open and start to close.
3. Continue to rotate engine slowly, watching
camshaft sprocket marks and the mark in the timing
inspection hole.
4. Align single (TDC) mark on flywheel with projection
in inspection hole, and the cam sprocket pin (facing
upward) aligned with the camshaft to crankshaft
center line. NOTE: The sprocket marks align with
gasket surface and the cam lobes should be
pointing down and valves should have clearance at
this point.
5. Remove cam chain tensioner plug, sealing washer,
spring and pin. CAUTION: The plug is under spring
tension. Maintain inward pressure while removing.
6. Remove the two 6x25 mm cam chain tensioner
flange bolts.
7. Tap lightly on tensioner body with a soft face
hammer and remove tensioner.
3.12
Single TDC Mark Aligned
TDC Mark
Rotation
Sprocket marks
align with gasket
surface
Do Not Use
Advance Marks