How to do a valve adjustment!!!!!! - Polaris ATV Forum
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post #1 of 3 (permalink) Old 02-04-2011, 02:48 AM Thread Starter
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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.


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post #2 of 3 (permalink) Old 02-04-2011, 03:58 AM
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From my 2002 sportsman 400/500 service manual:

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
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

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
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.

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
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
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post #3 of 3 (permalink) Old 02-04-2011, 07:04 AM Thread Starter
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thanks for the reply!!!!!
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