Polaris 2012 Sportsman Forest 500 International, Service Manual

Page: 101 / 432

3.46
ENGINE
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
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 the vehicle is
prepared 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.
Crankcase Assembly
1. Apply Crankcase Sealant ( PN 2871557 ) to the
crankcase mating surfaces. Be sure the alignment
pins are in place.
2. Set the crankcase in position carefully to avoid
damaging the pump shaft seal and install the magneto
end crankshaft installation tool (follow instructions
provided with the Crankshaft/Water Pump Installation
Kit
(PN 2871283) . Draw the crankcase halves
together by tightening the nut on the tool and tapping
lightly in the pump shaft area with a soft faced hammer
to maintain alignment. Continually check alignment of
the cases during installation, closing the gap equally
until the surfaces are tightly seated.
3. Remove the tool.
4. Install the crankcase flange bolts and tighten in 3
steps following the pattern on Page 3.3 to specified
torque.
Water Pump Mechanical Seal Installation
1. Clean the seal cavity to remove all traces of old
sealer.
2. Place a new mechanical seal in the seal drive collar,
and install on the pump shaft.
3. Screw the guide onto the end of the pump shaft.
4. Install the washer and nut and tighten to draw seal into
place until fully seated.
5. Remove the guide adaptor using the additional nut as
a jam nut if necessary.
Oil Pump Bolt Torque:
6. ft. lbs. (8 Nm)
Crankcase Bolt Torque:
14 ft. lbs. (19 Nm)
Crankcase Sealant:
(PN 2871557)