Polaris 2005 SPORTSMAN 400, Servise Manual, Page: 75 / 312

ENGINE
3.15
CAM CHAIN TENSIONER
INSPECTION
B
A
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.
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.
Tensioner Spring Free Length:
2.320
I
(5.9 cm)
4. Measure free length of tensioner spring. Replace
spring if excessively worn. Compare to
specifications.
5. Replace entire tensioner assembly if any part is
worn or damaged.
ROCKER ARM/SHAFT
INSPECTION
1. Mark or tag rocker arms to keep them in order for
assembly.
2. Inspect each rocker arm cam follower surface. If
there is any damage or uneven wear, replace the
rocker arm. NOTE: Always inspect camshaft
lobe if rocker arms are worn or damaged.
3. Measure O.D. of rocker shaft. Inspect it for wear
or damage. Compare to specifications.
Rocker Shaft O.D.:
.8656-.8661
I
(21.987-22.0 mm)