I'm replacing the camshaft on a 2004 Polaris Sportsman 500 and got to the point of reinstalling the sprocket and I'm having trouble with the chain. I can seat the chain back onto the sprocket wheel, no problem... but then the chain is too tight to allow me to fit the sprocket over the line up rod and plant the 3 bolts. I'm afraid I may have to take apart the flywheel assembly but I was hoping someone knows a trick. Everything I've read and heard suggests turning over the engine manually, with the sprocket already in place, while slowly guiding the chain over the sprocket during the turn (The way we fixed a chain on a bicycle as kids). The problem with that is that the previous owner broke the manual crank rope and its apparently gone or wrapped up inside there. Can someone please offer some tips? Any help is appreciated. Thank you.

 

Should be very easy to slip on the cam sprocket if you've removed the cam chain tensioner.If in doubt pull the flywheel and stator and have the single plated link on the crank sprocket at tdc,then the two plated links on the cam sprocket dots. Just like this one.https://atvconnection.com/forums/pol...ml#post3305250

 

Thanks so much for that link with pictures. Perfect example of how this forum can really pull together and help each other. So, if I remove the flywheel and stater, I'm assuming that would spill out oil, do pry best to drain my oil out beforehand right? And then I'll need new gaskets for that reassembly? This is my first quad and new to this scale of engine tinkering. Not completely green to it but still learning....LOTS of online videos and "How To's".

 

Mark the stator plate before you remove it. There may be a mark already on it and the case,but be sure you align it the way it was when the plate goes back on. Large o-ring around the plate and if you're careful you can reuse it. Small amount of oil will come out.Less oil drip if you lift up the right side a little.If you remove the slotted nut for any reason it's left hand threads. Use blue locktite on the threads and you can tighten the nut with a punch. The slotted socket isn't really needed.

 

Won't I need a puller to get that stater or flywheel off?or does it really need to be removed ?

 

Harmonic balancer puller or heavy duty steering wheel puller and (3) 8mm bolts to pull the flywheel. Stator plate has 10mm bolts.Same thing as pulling this 700 flywheel. You can rent these tools at most auto stores.