Polaris Outlaw 500, Service Manual

Page: 72 / 202

3.25
ENGINE
3
3. Separate crankcase by tapping with a soft faced hammer in
reinforced areas. Watch the gap along the crankcase mating
surface, making sure to separate the crankcase evenly. It
may also be necessary to tap the clutch side of the
crankshaft lightly to help separate the crankcase.
4. The crankshaft is designed to slip out of the PTO side upon
disassembly. Once the crankcase halves are split apart,
orientate the components into the stator side of the
crankcase containing the crankshaft, balancer, oil gallery,
the transmission gears and shift components for ease of
service and reassembly.
Crankcase Inspection
1. Remove all traces of gasket sealer from the crankcase
mating surfaces. Inspect the surfaces closely for nicks,
burrs or damage.
2. Check the oil pump and oil passage mating surfaces to be
sure they are clean and not damaged. Verify the oil pump
screen is clean.
Crankcase Bearing Inspection / Removal /
Installation
1. Inspect the crankshaft main bearings, balancer shaft
bearings, output shaft, and pump shaft bearings.
NOTE: Due to extremely close tolerances and
minimal wear, the bearings must be inspected
visually, and by feel. Look for signs of discoloration,
scoring or galling. Turn the inner race of each
bearing. The bearings should turn smoothly and
quietly. The outer race of each bearing should fit
tightly in the crankcase. The inner race should be
firm with minimal side to side movement and no
detectable up and down movement.
Bearing Removal:
NOTE: To ease bearing removal, warm the bearing
area, but not the bearing itself, until hot to the touch
to expand the bearing cavity.
1. Support the crankcase and drive or press the main bearings
out of each crankcase.
2. To remove balancer shaft bearings and pump shaft bearing,
use a blind-hole bearing puller.
NOTE: Bearings are stressed during the removal
process and should not be re–used!
Bearing Installation:
NOTE: For ease of bearing installation, warm the
crankcase until hot to the touch to expand the
bearing cavity. Place the bearings in a freezer. This
shrinks the bearing outer diameter slightly.
1. Install the bearings so the numbers are visible.
2. Drive or press new bearings into the crankcases, using the
proper driver.
IMPORTANT: Press only on outer race of bearing to
prevent bearing damage.
CAUTION
Wear the appropriate safety equipment during the
heating and removal process.
CAUTION
Wear the appropriate safety equipment during the
heating and installation process.