Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 105 / 289

GENERAL INFORMATION
3.47
1. Apply Polaris Premium Starter Drive Grease ( PN
2871460 ) to the camshaft main journals and cam
lobes. Lubricate automatic compression release
mechanism with clean engine oil. (To install the
compression release mechanism, refer to Page
3.17).
2. Install the camshaft with the lobes facing
downward and the sprocket alignment pin facing
upward.
Single (TDC)
Mark Aligned
3. Disconnect the wire from the cam chain and
rotate the engine to align the single (TDC ) timing
mark (Top Dead Center) on the flywheel with the
notch in the timing inspection window. Be sure to
use the single TDC mark when installing the cam.
Do not use the advance marks. See Ill. on next
page.
A
4. Loop the cam chain on the cam sprocket with the
dots on the sprocket facing outward and the
alignment pin notch facing directly upward.
A
B
5. Before positioning the sprocket on the camshaft,
check the position of the cam sprocket alignment
pin. When the cam is positioned properly, the
cam sprocket alignment pin (A) is directly in line
with the crankshaft/camshaft centerline (B).
6. Install the sprocket on the camshaft. Apply
Loctite
t
242 ( PN 2871949 ) to the cam sprocket
bolts and torque to specifications.
Cam Sprocket Bolt Torque:
6 ft. lbs. (8 Nm)
Single (TDC)
Mark Aligned
7. Verify TDC mark in timing inspection hole and
alignment pin is directly in line with crankshaft to
camshaft centerline. Refer to Ill. on following
page.
8. Apply Crankcase Sealant ( PN 2871557 ) to the
camshaft end cap and install using a new O-Ring.
9. Check all cam timing marks to verify proper cam
timing, and install the cam chain tensioner body
with a new gasket.
10. After tensioner installation, rotate engine at least
two revolutions and re-check marks/timing.