Polaris 2012 Sportsman Forest 500 International, Service Manual

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3.55
ENGINE
3
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
2. Apply starter drive grease to the drive bushing in the
crankcase and all moving surfaces of the starter drive
mechanism. Install the starter drive.
3. Install recoil housing gasket and recoil housing.
Rocker Shaft / Rocker Arm Assembly
Installation
1. Assemble rocker arms, rocker shaft, and shaft
supports.
2. Install and tighten rocker arm shaft locating bolt.
3. Apply starter drive grease to the cam lobes and cam
follower surfaces.
4. Rotate the engine until the cam lobes are pointing
downward.
5. Be sure the dowel pins are in place and install the
rocker shaft assembly.
6. Apply a light film of engine oil to the threads of the bolts
and tighten evenly.
7. Adjust valves according to the valve adjustment
procedure found in Chapter 2, Maintenance.
8. Apply clean engine oil liberally to the valve springs,
cam chain, rocker arms, and camshaft.
9. Place a new rocker cover gasket on the cylinder head
and install the cover and bolts.
Thermostat Installation
Install the thermostat with one of the air bleed holes
positioned next to the upper thermostat cover bolt hole as
shown.
Oil Pipes
Install the oil pipes with new sealing washers. Tighten all
bolts evenly to specified torque.
Oil Pump Priming Procedure
NOTE: The oil pump priming procedure must be
performed whenever the oil hose connection
between the oil tank and pump inlet has been
disconnected. Refer to the procedure in Chapter 2.
Starter Drive Grease:
(PN 2871460)
Rocker Shaft Support Tower Bolt Torque:
9 ft. lbs. (12 Nm)
Rocker Shaft Locating Bolt Torque:
6 ft. lbs. (8 Nm)
Apply Starter Drive
Grease to Bushing
Rocker Cover Bolt Torque:
6 ft. lbs. (8 Nm)
Oil Pipe Bolt Torque:
20 ft. lbs. (27 Nm)