Polaris 2007 Sportsman 450 EFI, Service Manual

Page: 98 / 406

3.40
ENGINE
ENGINE REASSEMBLY
Pump Shaft Oil Seal Installation
1. Install the seal from the outside of the crankcase (water
pump side) with the spring facing inward, toward the pump
shaft bearing.
2. Drive or press the seal into place using a 25 mm (.985") seal
driver, until flush with the outer edge of the seal bore.
3. Lubricate the seal lip with grease.
Crankshaft/Counter Balance/Oil Pump
Installation
Lubricate all bearings with clean engine oil before
assembly.
Use the Crankshaft/Water Pump Installation Kit (PN
2871283) to prevent damage to the crankshaft and main
bearings during installation.
1. Install the crankshaft into the PTO side crankcase. Screw
the threaded rod into the crankshaft until the threads are
engaged a minimum of one inch (25.4mm).
2. Install the collar, washer, and nut onto the threaded rod.
Hold the crankshaft and tighten the nut to draw the
crankshaft into the main bearings until fully seated. Loosen
the nut and remove the threaded rod from the crankshaft.
If removal is difficult, install two nuts on the end of the
threaded rod and tighten against each other.
3. Install the proper shim on the magneto end of the
crankshaft.
4. Place the balancer shaft in the PTO crankcase aligning the
timing marks on the crankshaft and balancer gears. Install
the proper shim washer on the shaft.
5. Inspect the oil pump sealing surface on the crankcase.
Apply a light film of engine oil to the surface and install the
oil pump.
NOTE: Do not use gasket sealer on the pump mating
surfaces.
NOTE: After engine is assembled and machine is
readied for field operation, oil pump MUST be primed.
Follow oil pump priming procedure
.
6. Align the drive gear with the drive pin on the pump shaft
and install the gear. Be sure the gear is fully seated and
properly engaged.
7. Install the proper shim washer on the pump shaft.
Oil Pump Bolt Torque:
6 ft. lbs. (8 Nm)