How to do a valve adjustment!!!!!! - Polaris ATV Forum
ATV Repair and Maintenance Having problems? Doing a rebuild? All Repair/Maintenance Discussions here.

 
LinkBack Thread Tools Display Modes
post #1 of 3 (permalink) Old 02-04-2011, 02:48 AM Thread Starter
ATV Enthusiast
 
chillmouser's Avatar
 
Join Date: Dec 2010
Location: Elliston
Posts: 33
Smile How to do a valve adjustment!!!!!!

Hi, Does anyone know how to do a valve adjustment on a 2002 sportsman 400, diagrams or video would be great!!!!!. Ihear a ticking or tapping sound while the bike is in idle.

thanks

chillmouser
chillmouser is offline  
Sponsored Links
Advertisement
 
post #2 of 3 (permalink) Old 02-04-2011, 03:58 AM
Extreme ATV Enthusiast
 
Nitro's Avatar
 
Join Date: Oct 2010
Location: Geneva, IL
Posts: 130
From my 2002 sportsman 400/500 service manual:

VALVE CLEARANCE
Inspect and adjust valve clearance while the engine is cold
and the piston positioned at Top Dead Center (TDC) on
compression stroke.
1. Remove the seat.
2. Remove body panels and fuel tank as necessary to
gain access to valve cover.
3. Remove the spark plug high tension lead and remove
the spark plug. CAUTION: Place a clean shop towel
into the spark plug cavity to prevent dirt from entering.
4. Remove rocker cover bolts, cover and gasket.
NOTE: It may be necessary to tap cover lightly with a
soft-faced hammer to loosen it from the cylinder head.
5. Remove timing inspection plug from recoil housing.
CAUTION: Failure to position the crankshaft at TDC on
compression stroke will result in improper valve adjustment.
6. Rotate engine slowly with recoil rope, watching the
intake valve(s) open and close.
NOTE: At this point watch the camshaft sprocket locating
pin and slowly rotate engine until locating pin is facing upward,
directly in line with the crankshaft to camshaft center
line as shown. The camshaft lobes should be pointing
downward.
7. Verify accurate TDC positioning by observing the “T”
mark aligned with the pointer in the timing inspection
hole. In this position there should be clearance on all
valves.

INTAKE VALVE CLEARANCE ADJUSTMENT
1. Insert a .006″ (.15mm) feeler gauge between end of
intake valve stem and clearance adjuster screw.
2. Using a 10 mm wrench and a screwdriver, loosen
adjuster lock nut and turn adjusting screw until there is
a slight drag on the feeler gauge.
3. Hold adjuster screw and tighten adjuster lock nut
securely.
4. Re-check the valve clearance.
5. Repeat adjustment procedure if necessary until
clearance is correct with locknut secured.
6. Repeat this step for the other intake valve.

EXHAUST VALVE CLEARANCE ADJUSTMENT
NOTE: The exhaust valves share a common rocker arm,
and must be adjusted using two feeler gauges.
1. Insert .006 feeler gauge(s) between end of exhaust
valve stem and adjuster screw(s).
2. Loosen locknut(s) and turn adjuster screw(s) until
there is a slight drag on feeler gauge(s). NOTE: The
feeler gauge(s) should remain inserted during
adjustment of each valve. The Valve/Clutch Adjuster
(PA--44689) can be used to adjust the 500 engines
valves.
3. When clearance is correct, hold adjuster screw and
tighten locknut securely.
4. Re-check the valve clearance.
5. Repeat adjustment procedure if necessary until
clearance is correct with locknut secured.

2002 Sportsman 400
Nitro is offline  
post #3 of 3 (permalink) Old 02-04-2011, 07:04 AM Thread Starter
ATV Enthusiast
 
chillmouser's Avatar
 
Join Date: Dec 2010
Location: Elliston
Posts: 33
thanks for the reply!!!!!
chillmouser is offline  
Reply

  Lower Navigation
Go Back   Polaris ATV Forum > Polaris ATV Technical Discussions > ATV Repair and Maintenance

Quick Reply
Message:
Options

Register Now



In order to be able to post messages on the Polaris ATV Forum forums, you must first register.
Please enter your desired user name, your email address and other required details in the form below.

User Name:
Password
Please enter a password for your user account. Note that passwords are case-sensitive.

Password:


Confirm Password:
Email Address
Please enter a valid email address for yourself.

Email Address:
OR

Log-in









Human Verification

In order to verify that you are a human and not a spam bot, please enter the answer into the following box below based on the instructions contained in the graphic.



Thread Tools
Show Printable Version Show Printable Version
Email this Page Email this Page
Display Modes
Linear Mode Linear Mode



Similar Threads
Thread Thread Starter Forum Replies Last Post
Valve Adjustment maverick11 ATV Repair and Maintenance 3 11-03-2010 03:07 PM
valve adjustment info johnnyjaws ATV Performance Modifications 8 10-03-2010 02:02 PM
valve clearance/adjustment ericmichael54 Polaris Sportsman 4 07-18-2010 03:27 PM
Valve Adjustment Bionic Man ATV Repair and Maintenance 0 05-10-2010 07:55 PM
chain adjustment shane milstead ATV Repair and Maintenance 7 04-09-2010 02:49 PM

Posting Rules  
You may post new threads
You may post replies
You may not post attachments
You may not edit your posts

BB code is On
Smilies are On
[IMG] code is On
HTML code is Off
Trackbacks are On
Pingbacks are On
Refbacks are On

 
For the best viewing experience please update your browser to Google Chrome