3.22
ENGINE
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Camshaft Inspection
1.
Visually inspect each cam lobe for wear, chafing or
damage.
2.
Thoroughly clean the cam shaft, making sure the oil
feed holes are not obstructed.
3.
Measure height of each cam lobe using a micrometer.
Compare to specifications.
4.
Measure camshaft journal outside diameter (O.D.)
5.
Measure ID of camshaft journal bore.
Calculate oil clearance by subtracting journal OD from
journal bore ID. Compare to specifications.
NOTE: Replace camshaft if damaged or if any part is
worn past the service limit.
NOTE: Replace cylinder head if camshaft journal
bore is damaged or worn excessively.
Cylinder Head Removal
1.
Remove the two 6mm flange bolts (A) from cylinder
head.
See exploded view on next page.
2.
Loosen each of the four cylinder head bolts evenly
1/8 turn each time in a criss-cross pattern until loose.
3.
Remove bolts (B) and tap cylinder head lightly with a
plastic hammer until loose.
IMPORTANT: Tap only in reinforced areas or on thick
parts of cylinder head casting to avoid damaging the
thread.
4.
Remove cylinder head and head gasket.
Cam Lobe Height (Intake & Exhaust):
Std: 1.2884-1.2924” (32.726-32.826 mm)
Limit: 1.2766” (32.426 mm)
Camshaft Journal O.D.:
Mag & PTO End: 1.4935-1.4941”
(37.935-37.950 mm)
Camshaft Journal I.D.:
Mag & PTO End: 1.4963-1.4970”
(38.005-38.025 mm)
Lubrication holes
Lobe height
Journal O.D.
Journal
Camshaft Oil Clearance:
Std: .0022-.0035” (.055-.090 mm)
Limit: .0039” (.10 mm)
B
Summary of Contents for 2012 Sportsman Forest 500 International
Page 1: ...1 GENERAL 2 MAINTENANCE 3 ENGINE 4 FUEL SYSTEMS 5 BODY SUSPENSION...
Page 2: ...6 CLUTCH 7 FINAL DRIVE 8 TRANSMISSION 9 BRAKES 10 ELECTRICAL...
Page 3: ...NOTES...
Page 115: ...NOTES ENGINE 3 60...
Page 117: ...4 2 FUEL SYSTEM...
Page 139: ...NOTES CARBURATION AND FUEL SYSTEM 4 24...
Page 185: ...NOTES 500 EFI FUEL SYSTEM 4 70...
Page 212: ...NOTES...
Page 258: ...NOTES CLUTCHING 6 46...
Page 330: ...NOTES TRANSMISSION 8 24...
Page 424: ...NOTES ELECTRICAL 10 60...
Page 425: ...Located By Battery...
Page 426: ......
Page 427: ...Located By Transmission Breakout Resistor Module...
Page 428: ......
Page 429: ...Located By Battery...
Page 430: ......
Page 431: ...Located By Transmission Breakout Resistor Module...
Page 432: ......