How to Install the REV6 Ratcheting Cam Chain Tensioner (Polaris Engines)
If you’ve ever had your Polaris ATV or UTV engine jump timing on cold start, you’re not alone. It’s one of the most common (and expensive) issues caused by the stock OEM hydraulic cam chain tensioner. In this detailed how-to, we break down a smart solution: swapping out that unreliable stock tensioner for our upgraded mechanical ratcheting cam chain tensioner—a small part that makes a big difference.
Whether you ride a Polaris Sportsman 570, a side-by-side, or any other Polaris setup with a similar cam chain system, this upgrade can save you from catastrophic engine damage and give you peace of mind every time you fire it up.
Why Upgrade Your Cam Chain Tensioner?
The OEM hydraulic tensioner relies on oil pressure to keep the cam chain tight. But here’s the catch: that pressure doesn’t build up instantly at startup. So during those first few seconds, your cam chain is loose and could skip a tooth—or three. That’s all it takes to throw off your timing, bend some valves, or worse.
The REV6 mechanical ratcheting tensioner solves that problem. It maintains consistent, mechanical tension at all times—cold, hot, or idling on a trail. No delay. No slack. No guessing.
What’s in the REV6 Kit?
This isn’t some half-baked hack job. The REV6 kit includes everything you need for a clean install:
- Billet aluminum adapter
- Flange gasket
- Spacer
- Crush washer
- O-ring and plug
- Bolts
- Mechanical tensioner assembly
Each piece is precision-machined and ready to drop in—no guesswork, no missing hardware.
Tools You’ll Need
To complete this job, all you need are common hand tools most garage warriors already own:
- Flat blade screwdriver
- Needle nose pliers
- Crescent wrench
- Contact cleaner or brake cleaner
- Assembly lube
- Torque wrench (for 86 in-lbs)
- Slim metal rod (for locating top dead center)
That last one’s a game changer. Instead of relying on sketchy flywheel marks, we use a piston contact tool we developed that safely touches the piston top to find TDC without damaging anything.
Step-by-Step: Installing the Tensioner
- Find TDC: Use a slim metal rod or your preferred method to locate top dead center on the compression stroke.
- Clean Everything: Hit the area with contact cleaner. No one wants grit or grime in their cam chain tunnel.
- Retract the Tensioner: Push the piston back and hold it down with the locking pin.
- Install Adapter & Gasket: Carefully line them up and finger-tighten the bolts.
- Apply Assembly Lube: Lube the moving parts and O-ring to help with seating and long-term performance.
- Torque to Spec: Use a torque wrench and go 86 inch-pounds, tightening evenly to avoid stripping the aluminum.
- Double Check Timing: Rotate the engine by hand and confirm that the cam marks still line up. If they’re off, stop and recheck everything.
Tips from the REV6 Garage
- Don’t overtighten. Stripping soft aluminum is easier than you think. Respect the torque spec.
- Stay clean. A tiny bit of dirt or aluminum burrs can throw off the whole install or wear parts prematurely.
- Use thread locker. Blue Loctite on the bolts can help prevent vibration issues.
- Keep it simple. We purposely use accessible tools so even first-time DIYers can tackle the job with confidence.
Final Checks and Peace of Mind
Once everything’s bolted up, rotate the engine a few full turns. The tensioner will ratchet into place automatically. Recheck your cam alignment. If the marks are good, you’re golden. Fire it up, and you’ll hear the difference right away—no more start-up clatter, no more chain slap.
Want to See This Upgrade on Bigger Engines?
Want a walkthrough for a 900, 1000, or turbo Polaris engine? Drop us a comment and let us know. We’re all about helping you wrench smarter, not harder.
Stay Connected with REV6
Have questions about your install? Text us—we’re quick to respond.
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Upgrade with Confidence
This cam chain tensioner might be small, but it’s a powerhouse when it comes to protecting your engine. Whether you’re running trails, hauling gear, or blasting dunes, this upgrade gives you one less thing to worry about.
💥 Shop the Rev6 Cam Chain Tensioner Upgrade Kit Now
🔧 Need Help? Contact Our Team
To watch the complete tutorial, check out the video below:
