Polaris 2012 Sportsman Forest 500 International, Service Manual

Page: 109 / 432

3.54
ENGINE
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Cam Chain Tensioner Installation
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.
3. Install the spring, new sealing washer, and tensioner
plug.
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 Crankcase Sealant (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.
6. Seal stator wire grommet with Crankcase Sealant
(PN 2871557) or equivalent sealer.
Flywheel
1. Install flywheel, washer, and nut. Torque flywheel to
specification.
Starter Drive
1. Be sure the washer is positioned on the back of the
drive gear.
Tensioner Bolt Torque:
6 ft. lbs. (8 Nm)
Tensioner Plug Torque:
6.5 ft. lbs. (9 Nm)
B
A
Stator Plate Bolt Torque:
5 - 6.5 ft. lbs. (7 - 9 Nm)
Flywheel Nut Torque:
58 - 72 ft. lbs. (78 - 98 Nm)