Cam Chain Tensioner Installation; Stator, Flywheel And Starter Drive Installation - Polaris Ranger 500 2x4 2007 Service Manual

ENGINE

Cam Chain Tensioner Installation

1. Release the ratchet pawl (A) and push the tensioner
plunger (B) all the way into the tensioner body.
A
2. Install the tensioner body with a new gasket and tighten the
bolts.
Tensioner Bolt Torque:
6 ft. lbs. (8 Nm)
3. Install the spring, new sealing washer, and tensioner plug.
Tensioner Plug Torque:
17 ft. lbs. (23 Nm)
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 Crankcase Sealant (PN 2871557) or an equivalent
sealer to the stator plate outer surface and install a new O-
Ring.
3.48
4.
B
NOTE: This is a static timing mark. Strobe timing
should be performed after start up.
5.
6.
Flywheel
1.
Starter Drive
1.
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.
Torque bolts evenly to specification.
Stator Plate Bolt Torque:
5 - 6.5 ft. lbs. (7 - 9 Nm)
Seal stator wire grommet with Crankcase Sealant (PN
2871557) or equivalent sealer.
Install flywheel, washer, and nut. Torque flywheel to
specification.
Flywheel Nut Torque:
58 - 72 ft. lbs. (78 - 98 Nm)
Be sure the washer is positioned on the back of the drive
gear.