Polaris SPORTSMAN 400 2003 Service Manual page 65

ENGINE
ENGINE REMOVAL
REFER TO PAGE 3.7- -3.8 FOR ENGINE
REMOVAL / INSTALLATION NOTES.
CAM CHAIN
TENSIONER/ROCKER
ARM/CAMSHAFT REMOVAL
1. Remove ignition timing inspection plug from recoil
housing.
TDC "T" Mark
Rotation
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
cam lobe should be pointing down and valves
3.14
Advance Marks
should have clearance at this point.
5. Remove cam chain tensioner plug, sealing
washer, and spring. 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.