my 00 500 chain won't tighten very easily and seems to get loose quick. i loosen the bottom caliper bolts and the 2 axle carrier bolts , am i missing anything else? what do you all use to tighten the chain? i've tryed chanell locks around the big nut, but might try a large cresent . thanks ,Erik

 

After you loosen all of the bolts, stick a metal punch or other strong object through one of the holes in the rotor. There is an indent (a few of them actually) on the other side. This will lock everything together when you try to roll the quad. Then, SLOWLY roll the quad forward to tighten the chain. If you go too far, you can roll it backward. This works fine on my '98 500. Once you get it to the right tightness, tighten everything else back up, and don't forget to remove the punch! Hope that makes sense, and isn't too vague or weird sounding. Also, with this method, you don't have to compress the suspension with a strap. Any ?'s or concerns, let me know and I might be able to make it more clear. Hope it helps.
Later,

 

First off get a torque wrench you are supposed to tighten them to 60 ft pounds.
trying to guess the right torque does not do it
Anyways after you loosen all the bolts tap them with a hammer to free anything up that is compressed under torque put a pucnh or screwdriver in the slot on your sprocket roll it ahead till it slides in too the hole in your axel housing.Then roll forward to your chain tightens to about 1 quater or 3/8 slack on your chain when you push on it.
as far as compressing your suspension you do not have to because of the concentric drive system it keeps a constant pressure not loose or tight under any load.
when you tighten everything up start with the caliper housing first.

Hope this helps good luck

 

I have the same problem with my 2000 Trailboss... it's back in the shop right now. They claim its normal to come loose.. mine loosens after about 10 miles. I've been pushing them to come up with a better answer.

 

Yeah i tried all that too and my chain kept loosening up too. Eventually the loose chain condition caused all the teeth to break off my output shaft sprocket. After replacing the sprocket i tighted the two bolts as tight as possible. I don't care if they break because they can be replaced. I was careful with the caliper bolts as they are threaded into an aluminum piece. The chain seems to remain tight ( Not really tight but snug ). Then the chain broke.

Chris Picciotto
99 Scrambler 500

 

I instaled a chain tensioner from hpd and that helps my chain stay tight a lot longer. also if you dont use a torque rench it will never stay tight very long.

 

Chain will probably stretch for awile when new. Use 96 Cobra's method for tightening but make sire the screwdriver or punch goes through both holes.

 

I have my Tboss in the shop because the chain keeps coming loose. They claim:
1) its normal to come loose
2) I stretched it by getting airborne and then landing with the wheels spinning (????)
3) They'll mark the concentric unit to see if its really coming loose (they admit they had to tighten it) Tehn I can go 2 hours up north just to have it loosen again.

When I asked why the chain rubbing against the chain guard, very loudly, they said "I dunno"

Is this what I should expect from a Polaris Dealer ?????