2005 Polaris Sportsman 400/500 Service Manual, Page 77Get this manual
Stop pin Spring in relaxed position A
B 1Check release lever shaft (A) for smooth operation throughout the entire range of rotationThe spring (B) should hold the shaft weight against the stop pinIn this position, the actuator ball (C) will be held outward in the compression release mode2Remove release lever shaft and return spring3Inspect shaft for wear or galling4Inspect lobe on end of release lever shaft and actuator ball for wear and replace if necessary
If Camshaft Is Removed From Engine: 3Turn the camshaft until the actuator ball is in the lowest position and install the release lever shaftIf Camshaft Is Installed In The Engine: 4Use small magnet to draw the actuator ball outward, or rotate the engine until the cam lobes face upward and install release lever shaft5Position camshaft as shown at bottom of illustration at right6Place arm of spring under stop pin as shown and push release lever inward until fully seatedDo not pre-wind the spring one full turn or the compression release will not disengage when the engine startsCheck operation of mechanism as outlined in Step of Removal (above)NOTE: When shaft is properly installed, actuator ball will be held in the "out" positionIt is important to note that spring pressure is very light