2005 Polaris Sportsman 400/500 Service Manual, Page 46Get this manual
MAINTENANCE CAUTION: Failure to position the crankshaft at TDC on compression stroke will result in improper valve adjustmentSprocket alignment pin facing up
INTAKE VALVE CLEARANCE ADJUSTMENT
1Insert .006 (.15mm) feeler gauge between end of intake valve stem and clearance adjuster screw2Using 10 mm wrench and screwdriver, loosen adjuster lock nut and turn adjusting screw until there is slight drag on the feeler gauge3Hold adjuster screw and tighten adjuster lock nut securely4Re-check the valve clearance5Repeat adjustment procedure if necessary until clearance is correct with locknut secured6Repeat this step for the other intake valveINTAKE VALVE CLEARANCE .006 (.15 mm)
Crankshaft-to-Camshaft Centerline 6Rotate engine slowly with recoil rope, watching the intake valve(s) open and closeNOTE: At this point watch the camshaft sprocket locating pin and slowly rotate engine until locating pin is facing upward, directly in line with the crankshaft to camshaft center line as shownThe camshaft lobes should be pointing downward