Crankcase Assembly - Polaris Sportsman 400 Service Manual

ENGINE
CRANKSHAFT/COUNTER BALANCE/OIL PUMP INSTALLATION
Lubricate all bearings with clean engine oil before assembly.
Use the crankshaft installation tool kit PN 2871283 to prevent damage to the crankshaft and main bearings during
installation.
1. Install the crankshaft into the PTO side crankcase. Screw the threaded rod into the crankshaft until the
threads are engaged a minimum of one inch (25.4mm).
2. Install the collar, washer, and nut onto the threaded rod. Hold the crankshaft and tighten the nut to draw the
crankshaft into the main bearings until fully seated. Loosen the nut and remove the threaded rod from the
crankshaft. If removal is difficult, install two nuts on the end of the threaded rod and tighten against each other.
3. Install the proper shim on the magneto end of the crankshaft.
4. Place the balancer shaft in the PTO crankcase aligning the timing marks on the crankshaft and balancer
gears. Install the proper shim washer on the shaft.
5. Inspect the oil pump sealing surface on the crankcase. Apply a light film of engine oil to the surface and install
the oil pump.
NOTE: Do not use gasket sealer on the pump mating surfaces.
NOTE: After engine is assembled and machine is readied for field operation, oil pump MUST be primed. Follow
oil pump priming procedure on page 3.13.
Oil Pump Bolt Torque:
6. ft. lbs. (.828 kg-m)
6. Align the drive gear with the drive pin on the pump shaft and install the gear. Be sure the gear is fully seated
and properly engaged.
7. Install the proper shim washer on the pump shaft.

CRANKCASE ASSEMBLY

1. Apply 3 Bond 1215 (P/N 2871557) to the crankcase mating surfaces. Be sure the alignment pins are in place.
2. Set the crankcase in position carefully to avoid damaging the pump shaft seal, and install the magneto end
crankshaft installation tool (follow instructions provided with tool kit PN 2871283). Draw the crankcase halves
together by tightening the nut on the tool and tapping lightly in the pump shaft area with a soft faced hammer to
maintain alignment. Continually check alignment of the cases during installation, closing the gap equally until
the surfaces are tightly seated.
3. Remove the tool.
4. Install the crankcase flange bolts and tighten in 3 steps following the pattern on page 3.2 to specified torque.
Crankcase Bolt Torque:
14 ft. lbs. (19-20 Nm)
3.60
- projex@inbox.lv -
Crankcase Sealant:
PN 2871557