Polaris Ranger 500 2x4 2007, Service Manual

Page: 105 / 345

3.46
ENGINE
IMPORTANT: CAMSHAFT TIMING NOTE: In order to
time the camshaft to the crankshaft, the piston must
be precisely located at Top Dead Center (TDC).
Camshaft Timing
1. Apply Polaris Premium Starter Drive Grease (PN
2871460) to the camshaft main journals and cam lobes.
Lubricate automatic compression release mechanism with
clean engine oil. (To install the compression release
mechanism, refer to Page 3.21).
2. Install the camshaft with the lobes facing downward and the
sprocket alignment pin facing upward.
3. Disconnect the wire from the cam chain and rotate the
engine to align the single (TDC ) timing mark (Top Dead
Center) on the flywheel with the notch in the timing
inspection window. Be sure to use the single TDC mark
when installing the cam. Do not use the advance marks.
4. Loop the cam chain on the cam sprocket with the dots on
the sprocket facing outward and the alignment pin notch
facing directly upward.
5. Before positioning the sprocket on the camshaft, check the
position of the cam sprocket alignment pin. When the cam
is positioned properly, the cam sprocket alignment pin (A)
is directly in line with the crankshaft / camshaft centerline
(B).
6. Install the sprocket on the camshaft. Apply Loctite™ 242
(PN 2871949) to the cam sprocket bolts and torque to
specifications.
7. Verify TDC mark in timing inspection hole and alignment
pin is directly in line with crankshaft to camshaft centerline.
Refer to Illustration on the following page.
8. Apply Crankcase Sealant (PN 2871557) to the camshaft
end cap and install using a new O-Ring.
9. Check all cam timing marks to verify proper cam timing,
and install the cam chain tensioner body with a new gasket.
10. After tensioner installation, rotate engine at least two
revolutions and re-check marks/timing.
Single (TDC)
Mark Aligned
Cam Sprocket Bolt Torque:
6 ft. lbs. (8 Nm)
Pin Notch
A
B