Polaris 2000 120 XCR, Service Manual

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4.16
ENGINE / CARBURETOR / CLUTCH
23. Torque band nut (E) to 6 ft.lbs (8.3Nm).
24. Route cables through harness guide clips.
25. Place gasket so raised edge is toward exhaust pipe.
26. Install exhaust to engine.
27. Torque manifold nuts to 18 ft.lb (25Nm).
28. Torque exhaust mounting bolt to 18 ft.lb (25Nm).
29. Install the clutch guard and torque the fasteners to 36 in.lb
(4Nm).
30. Connect the fuel line to the carburetor.
31. Fill fuel tank with fuel.
32. Fill engine crankcase with oil.
33. Start engine and check operation.
ENGINE COMPONENTS
CYLINDER & CRANKCASE
The cylinder and crankcase assembly is a single piece of
aluminum diecasting. The cylinder liner, made of special cast
iron, is molded into the aluminum casting. The crankcase has a
mounting surface on the output shaft side, where the main
bearing cover is attached.
MAIN BEARING COVER
The main bearing cover is an aluminum diecasting, which is
mounted on the output shaft side of the crankcase. Remove the
main bearing cover to inspect the inside of the engine.
CRANKSHAFT
The crankshaft is forged carbon steel, and the crank pin is
induction-hardened. The output end of the shaft has a crankshaft
gear, which is pressed into position.
CONNECTING ROD AND PISTON
The connecting rod is an aluminum alloy diecasting, and its
large and small ends function as bearings. The piston is an
= T
Band nut 6 ft.lbs (8.3Nm)
= T
Manifold Nuts 18 ft.lb (25Nm)
=
T
Exhaust Mounting Fasteners 18 ft.lb (25Nm)
=
T
Clutch guard fasteners 36 in.lb (4Nm)
E