Polaris SPORTSMAN 400 2003, Service Manual, Page: 100 / 274

ENGINE
3.49
CAM CHAIN TENSIONER
INSTALLATION
B
A
1. Release the ratchet pawl (A) and push the
tensioner plunger (B) all the way into the
tensioner body.
2. Install the tensioner body with a new gasket and
tighten the bolts.
Tensioner Bolt Torque:
6 ft. lbs. (8 Nm)
3. Install the spring, new sealing washer, and
tensioner plug.
Tensioner Plug Torque:
17 ft. lbs. (23 Nm)
4. Slowly rotate engine two to three revolutions and
re-check cam timing.
STATOR, FLYWHEEL AND
STARTER DRIVE
INSTALLATION
NOTE: The stator, flywheel, starter drive, and recoil
can be assembled with the engine in the frame.
Stator
1. Apply a light film of grease to the crankshaft seal.
Apply molybdenum disulfide grease or assembly
lubricant to the crankshaft bushing.
2. Install a new O-Ring in the oil passage recess in
the crankcase.
3. Apply 3 Bond 1215 (PN 2871557) or an
equivalent sealer to the stator plate outer surface
and install a new O-Ring.
4. Install the stator plate being careful not to damage
the seal. Align timing reference marks on the
plate and crankcase. Be sure the plate is fully
seated.
NOTE: This is a static timing mark. Strobe timing
should be performed after start up.
5. Torque bolts evenly to specification.
Stator Plate Bolt Torque:
5-6.5 ft. lbs. (7-9 Nm)
6. Seal stator wire grommet with Crankcase Sealant
(PN 2871557) or equivalent sealer.
Flywheel
1. Install flywheel, washer, and nut. Torque flywheel
to specification.
Flywheel Nut Torque:
58-72 ft. lbs. (78-98 Nm)
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