Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 95 / 289

GENERAL INFORMATION
3.37
5. Measure the connecting rod big end radial
clearance.
Big End Radial Clearance:
Std: .0004-.0015
I
(.011-.038 mm)
Limit: .0020
I
(.05 mm)
6. Inspect the crankshaft main bearing journals for
scoring and abnormal wear.
CRANKCASE BEARING
INSPECTION
1. Remove the seal from the PTO side crankcase.
2. Inspect the crankshaft main bearings, balancer
shaft bearings, and pump shaft bearing.
NOTE: Due to extremely close tolerances and
minimal wear, the bearings must be inspected
visually, and by feel. Look for signs of discoloration,
scoring or galling. Turn the inner race of each bearing.
The bearings should turn smoothly and quietly. The
outer race of each bearing should fit tightly in the
crankcase. The inner race should be firm with
minimal side to side movement and no detectable up
and down movement.
3. Support the crankcase and drive or press the
main bearings out of each crankcase.
4. To remove balancer shaft bearings and pump
shaft bearing use a blind hole bearing puller.
NOTE: Bearings are stressed during the removal
process and should not be re-used!
PUMP SHAFT OIL SEAL/
WATER PUMP MECHANICAL
SEAL REMOVAL (ENGINE
DISASSEMBLED)
NOTE: The water pump mechanical seal can be
removed without removing the engine. Refer to Water
Pump Mechanical Seal Installation.
Replace the pump shaft seal and water pump
mechanical seal whenever the crankcase is
disassembled.
1. Remove the pump shaft bearing from the
Magneto (right hand) side crankcase.
2. Pry out the oil seal, noting the direction of
installation with the spring side facing IN (toward
inside of case).
3. Drive the water pump mechanical seal out of the
crankcase from inside to outside. Note: The new
mechanical seal must be installed after the
crankcases are assembled, using a special tool.
See Mechanical Seal Installation.
CRANKCASE INSPECTION
1. Remove all traces of gasket sealer from the
crankcase mating surfaces. Inspect the surfaces
closely for nicks, burrs or damage.
2. Check the oil pump and oil passage mating
surfaces to be sure they are clean and not
damaged.