Polaris SPORTSMAN 400 2003, Service Manual, Page: 89 / 274

ENGINE
3.38
BEARING INSTALLATION
NOTE: To ease bearing installation, warm the
crankcase until hot to the touch. Place the bearings in
a freezer.
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.
S
70 mm (2.755 ) driver- For
crankshaft main bearings.
S 46 mm (1.810 ) For counter balancer
bearings.
S 28 mm (1.100 ) For pump shaft
bearing.
END PLAY
INSPECTION/ADJUSTMENT
Before reassembling the crankcase,the following
steps should be performed to determine the amount
of crankshaft, counter balancer shaft, and pump shaft
end play. Excessive end play may cause engine noise
at idle and slow speeds. Too little play will side load
the bearings which may lead to premature bearing
failure.
CRANKSHAFT END PLAY
ADJUSTMENT
1. Make sure all bearings are firmly seated in the
both Mag and PTO crankcase.
2. Measure the distance from the PTO crankcase
mating surface to the main bearing using a dial
caliper and a straight edge.
3. Subtract the thickness of the straightedge from
the measurement obtained in Step 2 and record.
PTO Case Depth
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