GENERAL INFORMATION
3.49
CAM CHAIN TENSIONER
INSTALLATION
B
A
1. Release the ratchet pawl (A) and push the
tensioner plunger (B) all the way into the
tensioner body.
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 3 Bond 1215 (
PN 2871557
) or an
equivalent sealer to the stator plate outer surface
and install a new O-Ring.
4. 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.
NOTE:
This is a static timing mark. Strobe timing
should be performed after start up.
5. Torque bolts evenly to specification.
Stator Plate Bolt Torque:
5-6.5 ft. lbs. (7-9 Nm)
6. Seal stator wire grommet with Crankcase Sealant
(
PN 2871557
) or equivalent sealer.
Flywheel
1. Install flywheel, washer, and nut. Torque flywheel
to specification.
Flywheel Nut Torque:
58-72 ft. lbs. (78-98 Nm)
Summary of Contents for 2004-2005 Sportsman 6x6
Page 1: ...SPORTSMAN 6X6 6 59 0 18 31 504 SPORTSMAN 6X6 6 59 0 18 31 504...
Page 58: ...MAINTENANCE 2 38 NOTES...
Page 78: ...GENERAL INFORMATION 3 20 CYLINDER HEAD EXPLODED VIEW EH50PL EH50PL...
Page 126: ...GENERAL INFORMATION 4 14 NOTES...
Page 142: ...GENERAL INFORMATION 5 16 NOTES...
Page 198: ...GENERAL INFORMATION 7 30 NOTES...
Page 276: ...ELECTRICAL 10 48 NOTES...
Page 277: ...ELECTRICAL WIRING DIAGRAM 2004 SPORTSMAN 6X6...
Page 278: ...ELECTRICAL WIRING DIAGRAM 2004 SPORTSMAN 6X6 NOTES...
Page 279: ...ELECTRICAL WIRING DIAGRAM 2005 SPORTSMAN 6X6 BUILT BEFORE JULY 12 2004...
Page 280: ...ELECTRICAL WIRING DIAGRAM 2005 SPORTSMAN 6X6 BUILT BEFORE JULY 12 2004 NOTES...
Page 281: ...ELECTRICAL WIRING DIAGRAM 2005 SPORTSMAN 6X6 BUILT AFTER JULY 12 2004...
Page 282: ...ELECTRICAL WIRING DIAGRAM 2005 SPORTSMAN 6X6 BUILT AFTER JULY 12 2004 NOTES...
Page 289: ...31 504 3ULQWHG LQ 86...