1999 sportsman 500 camshaft replacement - Polaris ATV Forum
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post #1 of 3 (permalink) Old 09-23-2019, 10:21 AM Thread Starter
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1999 sportsman 500 camshaft replacement

I could use some advice on replacing a camshaft on a 99 500 sportsman, put in new cam shaft but the timing chain gear is to tight for the holes to line up on the cam shaft. so I used a pry bar to lift up the gear and chain and got the holes to line up and got the 3 bolts in but now it is to tight to turn the motor with the pull rope. any advice would be appreciated not sure if it is the tensioner or what causing it to be so tight
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post #2 of 3 (permalink) Old 09-23-2019, 10:53 AM
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Originally Posted by johann1 View Post
I could use some advice on replacing a camshaft on a 99 500 sportsman, put in new cam shaft but the timing chain gear is to tight for the holes to line up on the cam shaft. so I used a pry bar to lift up the gear and chain and got the holes to line up and got the 3 bolts in but now it is to tight to turn the motor with the pull rope. any advice would be appreciated not sure if it is the tensioner or what causing it to be so tight
Uh... the cam has nothing to do with how tight the chain is.
Did you have the engine at TDC before starting to work on it?
Did you remove the tensioner FIRST before doing anything else?
Did you make sure the chain didn't slip off the bottom gear or that there's not a kink in the chain at the bottom gear before you started prying on it with a pry bar?
Remove the tensioner and remove the cam gear. Get the engine at TDC and start over. Hopefully you haven't damaged anything trying to force it on that way.
You just put the gear in the chain with your fingers and then bolt the gear to the cam. THEN you lock the tensioner fully retracted to install and set it and check to see that its still in time. If not you have to take it back off and move a tooth one way or the other.
There's dozens of videos on YouTube, Partzilla and other places. Some are good and some not so good but you should probably spend some time watching a few.
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post #3 of 3 (permalink) Old 09-24-2019, 02:36 PM Thread Starter
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thank you for your reply.

It was the chain tensioner that caused the issue removed the bolt but not the whole thing which contained a locking shaft that put pressure on the chain .
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