Polaris PREDATOR 2003, Service Manual

Page: 76 / 193

ENGINE
3.33
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. Wear the appropriate
safety equipment during the heating and removal
process.
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. Wear the appropriate
safety equipment during the heating and installation
process.
1. Install the bearings so the numbers are visible.
2. Drive or press new bearings into the crankcases,
using the proper driver. CAUTION: Press only on
outer race of bearing to prevent bearing damage.
PUMP SHAFT OIL SEAL/
WATER PUMP MECHANICAL
SEAL REMOVAL (ENGINE
DISASSEMBLED)
NOTE: The water pump mechanical seal can be
removed without removing the engine. Refer to Water
Pump Mechanical Seal Installation.
Replace the water pump mechanical seal whenever
the crankcase is disassembled.
1. Remove the pump shaft bearings from the pto
(right hand) side crankcase.
2. Drive the water pump mechanical seal out of the
crankcase from inside to outside. NOTE: The
new mechanical seal must be installed after the
crankcases are assembled, using special tools.
See Mechanical Seal Installation.
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.
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