Polaris Outlaw 500, Service Manual

Page: 62 / 202

3.15
ENGINE
3
4. To retract the plunger, rotate the special tool clockwise
while holding the tensioner stationary. You may also hold
the special tool stationary and rotate the tensioner assembly
counterclockwise if desired.
IMPORTANT: Do not grind edges of key flange into
tensioner to prevent damage to the tool or locking
guides during plunger retraction.
5. Once retraction is complete, lock the tool into the tensioner
guides. This holds the spring and plunger in place for
reassembly. Use caution not to disturb the tool during
tensioner installation.
6. Reinstall the tensioner assembly, torquing the bolts to
specification (Page 3.3). Remove the special tool and
replace the tensioner cap.
Camshaft Removal
1. Remove the valve cover.
2. Remove the tensioner assembly.
3. Remove the 8 bolts securing the cam tower assembly and
remove the cover.
4. To free the cam assembly, lift one cam assembly and
slightly rotate it while removing the chain from the cam
gear. Repeat this procedure for the other cam.
NOTE: Do not allow cam chain to drop into the
engine if no other disassembly is being performed.
5. Use a device to secure the cam chain, such as mechanic’s
wire or nylon line, to prevent it from falling into the engine.
6. Inspect cam sprocket teeth for wear or damage. If damage
is found, replace the camshaft assembly.
Automatic Compression Release Inspection
NOTE: The automatic compression release
mechanism cannot be serviced. The components are
not replaceable. Replace the camshaft as an
assembly if any part of the compression release is
worn or damaged.
1. Check release cam (A) for smooth operation throughout
the entire range of movement. The spring (B) should hold
the cam against the stop. In this position, the actuator (C)
will be held outward in the compression release mode.
2. Inspect lobe on end of release cam for wear. Replace cam
assembly if necessary.
Tensioner Bolt Torque
6.6- 8.1 ft lbs (9- 11 Nm)
Inspect for Areas of Tooth
Wear or Damage
Note: Cam and compression release are
an assembly and not serviceable .
A
B
C