Polaris Outlaw 500, Service Manual

Page: 61 / 202

3.14
ENGINE
UPPER ENGINE DISASSEMBLY
Disassembly
REFER TO PAGE 3.8-3.9 FOR ENGINE
REMOVAL / INSTALLATION NOTES
Cam Chain Tensioner Removal
1. Remove ignition timing inspection plug from recoil
housing.
To position crankshaft at Top Dead Center (TDC) on the
compression stroke:
2. Rotate engine slowly in the direction of rotation watching
intake valves open and start to close.
3. Continue to rotate engine slowly, watching for the camshaft
sprocket marks and the indicator mark in the timing
inspection hole.
4. Align the indicator mark on flywheel with the indent in the
inspection hole and the cam sprocket marks (facing
upward) aligned with the dots at the 12 o’clock and 9
o’clock positions.
NOTE: The cam lobes should be laying flat and the
valves have clearance at this point.
5. Remove the two 8 x 25 mm cam chain tensioner flange
bolts.
6. If tensioner remains in place, tap lightly on tensioner body
with a soft face hammer and remove tensioner.
7. For installation, retract the plunger using the special tool
and reverse the installation procedures using a new gasket.
Tighten bolts to specification. (Page 3.3)
Cam Chain Tensioner Inspection and
Reassembly
NOTE: The cam tensioner assembly is not a
serviceable item. Replace assembly if problems are
found. Spring tension may be relieved using the
special tool prior to removal, but is not necessary.
1. When removed, the cam chain tensioner plunger should be
extended outward to the end of its travel. Verify and
inspect the plunger for wear or damage.
2. Push on the plunger. The plunger should not move in and
out of the tensioner body.
3. To release the plunger tension and prepare for reassembly,
remove the 10mm plug and insert the Cam Chain Tensioner
Tool
(PA-45958) , lodging the tip of the tool into the spring
TDC Line
(Left of the “T”)
TDC
Case Mark
CAUTION
The assembly is under spring tension.
Maintain inward pressure while removing.
A- Tool PN PA-45958
B- 10mm tensioner cap
A
B
Tool PA-45958
IMPORTANT
Maintain Clearance
while rotating tool
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