Polaris 2005 Sportsman MV7, Service Manual

Page: 104 / 312

ENGINE
3.46
Camshaft Journal O.D. :
A. (Mag): 1.654”
±
.00039” (42
±
.010 mm)
B. (Ctr.): 1.634”
±
.00039” (41.50
±
.010 mm)
C. (PTO): 1.614”
±
.00039” (41
±
.010 mm)
5. Measure ID of camshaft journal bores.
Camshaft Journal Bore I.D.:
(Mag): 1.656”
±
0.00039” (42.07
±
0.010 mm)
(Ctr.) 1.637”
±
0.00039” (41.58
±
0.010 mm)
(PTO) 1.617”
±
0.00039” (41.07
±
0.010 mm)
6. Calculate oil clearance by subtracting journal
O.D.’s from journal bore I.D.’s. Compare to
specifications.
Camshaft Oil Clearance:
Std: 0.00118” (.0299mm)
Limit: .0039” (.10 mm)
NOTE: Replace camshaft if damaged or if any part
is worn past the service limit.
NOTE: Replace engine block if camshaft journal
bores are damaged or worn excessively.
ENGINE CRANKCASE
REASSEMBLY
WARNING: After any reassembly or
rebuild, the engine must be primed using
the Oil Priming Adapter (PU--45778) and
a 3/4--full oil filter before initial start--up.
Follow Steps 45--46 in this section to
properly prime the engine and to help aid
proper engine break in.
NOTE: Before assembly, clean the bolts and bolt
holes with Primer N ( PN 2870585 ) to remove any
debris. This will ensure proper sealing when installing
bolts.
1. Install oil pick up (A), if removed. Torque bolt to 60
±
6 in. lbs. (6.8
±
0.68 Nm).
A
B
2. Install oil baffle weldment (B). Torque bolts to 60
±
6 in. lbs. (6.8
±
0.68 Nm).
Oil Baffle Weldment & Oil Pick Up-
Bolt Torque:
60
±
6 in. lbs. (6.8-0.68 Nm)
3. Install the balance shaft. Inspect balance shaft
clearance (C) in both gearcase halves. Rotate
balance shaft to ensure that there is clearance
between it and oil baffle weldment.
NOTE: Always install new balance shaft bearings.
C