Counterbalance Shaft Removal / Inspection; Counterbalance Split Gear Replacement - Polaris 2009 Sportsman XP 850 Service Manual

ENGINE

Counterbalance Shaft Removal / Inspection

1. Note timing marks on balance shaft drive gears and
crankshaft drive gear. Shafts must be properly timed upon
assembly.
2. Mark each shaft location for assembly (starter side or oil
pipe side).
3. Lift both balance shafts from upper crankcase and remove
end plugs.
4. Inspect both counterbalance shaft bearings.
NOTE: Due to extremely
counterbalance shaft bearings must be inspected
visually, and by feel. Look for signs of discoloration,
scoring, galling, or contamination from moisture or
dirt. Turn bearings on shaft. Bearings should turn
smoothly and quietly. The outer race should be firm
with minimal side to side movement and no
detectable up and
bearings if any of the above are present.
5. Inspect gear teeth for damage. Normal split gear alignment
is approximately 1/2 tooth in the relaxed position as shown.
5.44
close tolerances,
down movement. Replace
6. Hold main gear (A) and rotate split gear counterclockwise
(viewed from gear end) to compress springs. Split gear
should rotate and return freely and completely without
binding.
A

Counterbalance Split Gear Replacement

1. Set shaft upright in a press with gear fully supported on
each side with a flat press plate. Select a suitable arbor
(slightly smaller than the O.D. of the shaft), and press shaft
out of bearing and then out of gear assembly.
NOTE: Do not attempt to press off the thrust washer
with the split gear. The washer is positioned behind
the alignment pin and can only be replaced if the pin
is removed (see the following illustration).