Polaris 2004-2005 Sportsman 6x6, Service Manual

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GENERAL INFORMATION
3.35
9. Measure pump end clearance using a feeler
gauge and straight edge.
Pump End Clearance:
Std: .001-.003 (.0254-.0762 mm)
Wear Limit: .004 (.1016 mm)
10. Measure clearance between outer feed rotor and
pump body with a feeler gauge.
Rotor Tip Clearance:
Std: .005 (.127 mm)
Wear Limit: .008 (.2032 mm)
11. Measure rotor tip clearance with a feeler gauge.
12. Remove inner and outer feed rotor and pump
chamber body.
13. Repeat measurements for scavenge rotor.
14. Remove inner and outer scavenge rotor and
inspect pump shaft for wear.
OIL PUMP ASSEMBLY
1. Clean and dry all parts thoroughly. Apply clean
engine oil to all parts. Do not use gasket sealer on
the pump body mating surfaces or oil passages
will become plugged.
2. Install pump shaft and scavenge rotor drive pin.
3. Install outer scavenge rotor, inner scavenge rotor,
and scavenge casing.
4. Install outer feed rotor and inner feed rotor drive
pin.
5. Install inner feed rotor and feed chamber cover
with screw.
6. Tighten screw securely.
7. Install screen on pump body.
8. Install oil pump on crankcase and torque bolts to 6
ft. lbs. (8 Nm).
Oil Pump Attaching Bolt Torque:
6 ft. lbs. (8 Nm)
COUNTER BALANCER
SHAFT
REMOVAL/INSPECTION
A
1. Remove the shim washer (A) from the counter
balancer shaft.