Engine Disassembly; Cam Chain Tensioner/Rocker Arm/ Camshaft Removal; Cam Chain Tensioner Inspection - Polaris 2007 Sportsman 500 EF Service Manual

ENGINE

ENGINE DISASSEMBLY

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.
3.14
NOTE: The cam lobe should be pointing down and
valves should have clearance at this point.
Advance Marks
5.
6.
7.

Cam Chain Tensioner Inspection

1.
Remove cam chain tensioner plug, sealing washer, and
spring.
CAUTION
The plug is under spring tension. Maintain inward
pressure while removing.
Remove the two 6x25 mm cam chain tensioner flange
bolts.
Tap lightly on tensioner body with a soft face hammer to
loosen and remove tensioner.
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.
A
B