Polaris Trail Boss 330 2003 Service Manual page 56

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.
Single TDC Mark Aligned
TDC Mark
Rotation
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.
Sprocket marks
align with gasket
surface
Do Not Use
Advance Marks
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.
CAM CHAIN TENSIONER
INSPECTION
1. Pull cam chain tensioner plunger outward to the
end of its travel. Inspect teeth on ratchet pawl (A)
and plunger teeth (B) for wear or damage.
B
A
2. Push ratchet pawl and hold it. The plunger should
move smoothly in and out of the tensioner body.
3. Release ratchet pawl and push inward on plunger.
It should remain locked in position and not move
inward.
ENGINE
3.11