ENGINE
3.55
CAM CHAIN/CAMSHAFT INSTALLATION
Install the cam chain over the crankshaft.
CAUTION: Serious engine damage may re-
sult if the camshaft is not properly timed to
the crankshaft.
IMPORTANT CAMSHAFT TIMING NOTE: In order to
time the camshaft to the crankshaft, the piston must be
precisely located at Top Dead Center (TDC). This can
be accomplished using one of two methods.
When the stator assembly is removed, follow the
procedure outlined in Method 1. This method uses the
cam chain plated links to time the camshaft and the dot
on the cam chain drive sprocket to establish TDC (see
below, Method 1). It is important to note that this meth-
od can only be used when the stator is removed and
the cam chain drive sprocket is in view. The plated
links are not used to time the camshaft when the fly-
wheel is installed.
When the stator assembly is installed use Method 2.
This method establishes accurate Top Dead Center
(TDC) by aligning the single mark on the flywheel with
the notch in the timing inspection hole (see Method 2,
page 3.58). The camshaft sprocket alignment marks
are parallel to the gasket surface, the alignment pin
faces to the intake side, and camshaft lobes are point-
ing down.
Camshaft Installation - Timing Method 1. Refer to Illustration, Page 3.57
If the stator assembly is removed: NOTE: Use this
method only when the stator is removed and cam
chain drive sprocket is in view.
1. Rotate the crankshaft until the mark on the cam
chain drive sprocket is aligned with the crankcase
projection (mark facing downward).
2. Align the single plated link on the cam chain with
the marked tooth of the cam chain drive sprocket.
Use a wire to pull the chain up through the cylinder
and cylinder head, and secure it to hold the chain
in place.
3. Apply Polaris Low Temp Grease PN 2870577, or
engine assembly lubricant to the camshaft main
journals and cam lobes. Lubricate automatic
compression release mechanism with clean
engine oil. (To install the compression release
mechanism, refer to page 3.18).
4. Install the camshaft with the lobes facing
downward and the sprocket alignment pin facing
toward intake.
5. Disconnect the wire from the cam chain and install
the cam sprocket with the dot facing outward.
6. Loop the cam chain over the cam sprocket,
aligning the plated link on the chain with the dot on
the sprocket.
Sprocket
Mark
Plated
Link
Crankcase
Projection
Plated link
aligned w/dot
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