Cam and Rocker Removal & Installation 98 Sportsman 500
#1
Hey guys new member here. Now before I get bashed for being the new guy and told to do my research on the forums that already covers this topic, I want to start off by introducing myself with some history and questions. I recently bought a used 98 Sportsman 500 Non HO for $700, previous owner mentioned he was only able to get it to start with starter fluid through the intake. I bought it after hearing the motor turn over with starter fluid knowing that it wasn’t locked up. I figured a carb clean or rebuild was definitely necessary given it appeared to have been sitting for some time. First wave of parts I purchased was a carb rebuild kit, New yuasa battery, New NGK Spark plug, Oil change kit from Polaris and a new CV boot for the rear axle. Stripped the carb down and rebuilt it, installed the new battery and spark plug and held off on the old change until after hopefully hearing a startup. Upon my first startup I had gas spewing and leaking from the header pipe while trying to turn it over, immediately turned the gas off and didn’t try it again. Something was up so I checked for any potential fuel leaks from hoses, overflow and fuel bowl and everything was bone dry, this told me I’m over fueling somehow as I’m literally watching it leak gas from the header pipe. I pulled the carb back apart and discovered the air fuel screw had snapped off flush in the carb body barrel. Didn’t bother trying to track down a shop at the moment to attempt to get it out as their all pretty busy right now and from what I hear most won’t even touch something like that happening. So the mikuni went on the table for now, I did a little research and checked with other members on a Polaris Facebook page and was hearing good things about the “Zoom Zoom” brand carburetors for my Sportsman, pulled the trigger on one for almost $80. Received the new carburetor in the mail, opened it up to confirm everything was set right and then installed it on the bike, same issue..still leaking gas from header pipe. I did more thinking and pondering and research and came to the conclusion that my exhaust cam lobe on my camshaft could be the culprit as most of you are probably aware is a big issue on these motors. I Immediately tore all the plastics off, pulled the tank and valve cover to access the Cam/Rockers, bumping the starter button (as the pull rope is missing) I completely rotated my cam enough to confirm the center lobe is completely gone. At this point I’m 99% sure that’s my problem, so I ordered an $80 Cam/Rocker and gasket kit off eBay and it just came in the mail today. Now here’s where my questions are, the cam removal process seems pretty straight forward...Confirm TDC, Remove Chain tensionser, Unbolt 3 bolts off Cam Gear and make sure my timing marks are labeled, hold chain and gear up with some wire off to the side, remove rocker arm assembly, remove upper coolant hose/elbow and lastly remove cover for cam to slide out..now given that is the correct sequence, my question is what are the torque specs for reinstalling any bolts that were removed during the entire sequence!??
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Thenson
Polaris Ask an Expert! In fond memory of Old Polaris Tech.
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Apr 10, 2018 06:22 PM
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