Engine Lower End Torque Specifications; Engine Lower End Specifications - Polaris 1999 Sportsman 400 Service Manual

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mancc and service life of the eng ine depends
grea tly on a careful and sensible break-in.
For the first 5- 10 hours o f op erati on. usc no
more than 1/3 throttle. and vary the speed as much
as possibl e within the 1/3 thrott le limit. Avo id
C HA PTE R FIVE
hard acceleration in add ition to prolonged steady
running at one speed, no matter how moderate.
Aller the initial 5- 10 hours of opera tion. usc pro-
gressive ly mo re throttle (with short bursts of speed)
until the ATV has run for another 10-15 hnur s.
Table 1 ENGINE LOWER END TORQUE SPECIFICATIONS
Item
Nom
In.·lb. It.·lb.
Breather un ion bolt 9-15 80-132
Crankcase mounting bolts 19-21
14-15
Crankcase oil dra in plug
19·2 3 14-17
Flywheel nut 80-99
58-72
Oil
delivery pipe
25·34
18·25
011 filter union bolt
50-59
36-43
Oil ho se union bolt
9-15 80-132
Oil pr essure blind plug 9-15 80-132
Oil
pump
Mounllng bolts 7-9 62-80
Cover screw 3 26
One-way valve plug
19-26 14-19
Recoil sta rte r housing bolts 7·9 62-80
Starter motor mounting bolts
7-9 62-80
Stator plate bolts 7-9 62-80
Water pump
Impeller nut 7-9 62·80
Cover bolts 7-9 62-80
Table 2 ENGINE LOWER END SPECIFICATIONS
Item
Conn ect ing rod
Piston pin bore d iameter
Pistlon pin en d play clearance
Side play
Bid end radia l cle arance
Cr ank sh aft runout li mit
One- way check valve spring
Oil pump (feed and scavenge)
Pump end clear ance
Ou ter rotor-to-body cl earance
Inn er rotor tip cl earance
Bal anc e sha ft en d play
Crankshaft end pl ay
011 pump end play
New
mm(ln.,
23.007-23.020
(0.9058-0 .9063 )
0.007-0.026
(0.0003-0.0010)
0.1·0.65
(0.0039-0.0256)
0.011-0.038
(0.004· 0.0015)
3.68
(1.450 )
0.0254-0.076 2
(0.001-0.00 3)
0 .0254-0.076 2
(0.001-0.003)
0.127
(0.005)
0.2-0 .4 (0.008-0.016)
0.2-0 .4 (0.008-0.016)
0.2-0 .4 (0.00 8-0.016)
Service limit
mm lin.)
0.05
0.80
(0.0315)
0.0020
(0.00 20)
0.06
(0.0024 )
0.1016
(0.004)
0.1016
(0.004)
0.2032
(0.008)