Polaris Outlaw 500, Service Manual

Page: 77 / 202

3.30
ENGINE
3. Place the crankshaft in a truing stand or V–blocks and
measure the runout on both ends with a dial indicator. See
Crankshaft Straightening on Page 3.10.
4. Measure the connecting rod big end radial clearance.
5. Measure the connecting rod small end radial clearance.
6. Measure the connecting rod small end I.D.
ENGINE REASSEMBLY
Crankcase Reassembly
1. Apply a thin layer of Crankcase Sealer ( PN 2871557 ) to all
sealing surfaces of the PTO case half, being careful not to
over apply, as excessive sealant may clog oil passages or
drip into the crankcase. Allow the sealer to set for a few
minutes before assembling the two halves together.
2. Align the crankshaft and balancer timing marks and insert
the components into the stator-side case halve. Then install
the oil tube and transmission assemblies.
3. Reassemble the crankcase halves. This is best
accomplished with the stator side casehalve settled in a
suitable fixture that allows it to lay flat. This allows easier
installation without parts falling out of position. Make sure
the oil gallery tube is oriented correctly and the balancer
shaft groove aligns with the water pump shaft. Refer to
photos.
NOTE: Some light tapping with a soft faced mallet
may be required to bring the casehalves together. If
for any reason the cases fail to mate, DO NOT
FORCE. Reverify the transmission assemblies are
fully seated in their respective case half and are not
binding.
4. Reinstall the (12) stator side and (1) clutch side flange bolts,
tightening in a criss-cross pattern. Stop occasionally and
check that all rotating assemblies turn freely. Torque the
flange bolts to
80–97 in. lbs. (9–11 Nm) .
Max Runout: .0012
″
(.03 mm)
Big End Radial Clearance:
Limit: .0004- .0015
″
(.011- .038 mm)
Small End Radial Clearance:
Limit: .0020
″
(.05 mm)
Small End I.D. :
Std: .9058- .9063
″
(23.007- 23.020 mm)
Align balancer
shaft and water
pump shaft grooves
Pin
Verify pin is aligned with notch in case
RepairPro Service Manual