2005 Polaris Sportsman 400/500 Service Manual, Page 108Get this manual
CAM CHAIN TENSIONER INSTALLATION
1Apply light film of grease to the crankshaft sealApply molybdenum disulfide grease or assembly lubricant to the crankshaft bushing2Install new O-Ring in the oil passage recess in the crankcase3Apply Bond 1215 (PN 2871557) or an equivalent sealer to the stator plate outer surface and install new O-Ring
1Release the ratchet pawl (A) and push the tensioner plunger (B) all the way into the tensioner body2Install the tensioner body with new gasket and tighten the boltsTensioner Bolt Torque: ftlbs(8 Nm) 3Install the spring, new sealing washer, and tensioner plugTensioner Plug Torque: 17 ftlbs(23 Nm) 4Slowly rotate engine two to three revolutions and re-check cam timing4Install the stator plate being careful not to damage the sealAlign timing reference marks on the plate and crankcaseBe sure the plate is fully seatedNOTE: This is static timing markStrobe timing should be performed after start up5Torque bolts evenly to specificationStator Plate Bolt Torque: 5-6.5 ftlbs(7-9 Nm) 6Seal stator wire grommet with Crankcase Sealant (PN 2871557) or equivalent sealerFlywheel 1Install flywheel, washer, and nutTorque flywheel to specificationFlywheel Nut Torque: 58-72 ftlbs(78-98 Nm)