Polaris Outlaw 500, Service Manual

Page: 80 / 202

3.33
ENGINE
3
3. If not already at Top Dead Center, Loosely hold the cam
chain and rotate the crankshaft until the crankshaft cam
sprocket timing mark is aligned with the Top Dead Center
(TDC) mark on the crankcase (see photo). Position the
chain for correct timing by aligning the bottom cam timing
mark with the brass colored bottom chain link. Keep
tension on the chain so as to not lose chain alignment at the
crankshaft sprocket during cam installation.
4. Install the camshafts one at a time. First, install the exhaust
cam by looping the chain over the cam gear. At the same
time, position the cam chain for correct timing by aligning
the brass colored chain link with the 12 o’clock dot on the
cam sprocket. The sprocket secondary mark should be at
the 9 o’clock position.
Keep tension on the chain so as to
not lose chain alignment at the crankshaft sprocket.
5. Next, install the intake cam, positioning the upper cam
chain for correct timing by aligning the remaining brass
colored chain link with the 12 o’clock dot on the cam
sprocket. Timing is in phase when all three brass colored
cam chain links align with all three sprocket timing marks
and the secondary cam gear marks are at approximately the
9 o’clock position, with the exhaust cam timing mark
slightly advanced. Refer to the diagram on Page 3.34.
NOTE: Failure to align marks in this fashion will
cause valve-to-piston interference, resulting in
engine damage.
6. Re-check all cam timing marks to verify proper cam timing,
and install the cam tower. Tighten the bolts evenly in a
criss-cross pattern to specification.
Do not rotate engine
until the tensioner has been installed to avoid chain slip
and loss of timing reference.
7. Install the tensioner assembly. (raefer to Page 3.14). Verify
timing by rotating the crankshaft two full revolutions (720
degrees), checking for valve-to-piston interference which
would indicate a problem with cam timing. If interference
is noted, immediately stop rotation and reverify cam
timing.
NOTE: Rotating the engine during verification will
cause the timing alignment marks to rotate out of
phase, and will take as many as 20 revolutions to
come back into phase. To maintain alignment of the
marks if needed, rotate the engine backward the
same number of turns as forward.
8. With timing procedure completed, install the primary drive
sprocket, washer and nut onto the crankshaft. Torque to
specification.
Primary Drive Gear Installation
1. Install the cam sprocket with alignment mark outward.
2. With chain in place and cam timing having been performed,
install the primary drive sprocket, washer and nut onto the
crankshaft. Torque to
81–96 ft. lbs. (110–130 Nm) .
Align Brass Colored Link and Sprocket
Mark with Top Dead Center (TDC) Mark
Align Brass Colored Link and Sprocket
Mark with Top Dead Center (TDC) Mark
Note exhaust cam is slightly advanced