Crankshaft Installation; Oil Passage Tube - Polaris 2009 Sportsman XP 850 Service Manual

Crankshaft Installation

Refer to illustration Crankcase Assembly (Upper) page 5.54.
1. Clean the bearing bore surfaces of upper crankcase (main
bearings), connecting rods, and connecting rod caps.
2. Align tab of a new main bearing with the slot in main
bearing bore of crankcase. Press bearing insert firmly into
place. Repeat for all main bearings, connecting rods, and
connecting rod caps.
3. Apply Premium Starter Grease (2871460) to each main and
rod bearing journal of crankshaft.
4. Loop cam chain over crankshaft sprocket.
5. Apply engine oil to new crankshaft seals and install seals
on both ends of crankshaft with spring side of seal facing
IN (toward crankshaft).
6. Carefully lower crankshaft into upper crankcase. Guide
connecting rods onto rod journals of crankshaft as
necessary.
7. Adjust crankshaft seals so each is flush with end of
crankcase.
8. Clean threads of bolts and threads in connecting rod to
remove all oil, grease, or assembly lubricant.
9. Apply Loctite 262 (Red) to the end 5 threads of rod bolts.
10. Install rod caps on rods with marks aligned.
11. Install new bolts and tighten evenly until snug.
12. Torque bolts using the following procedure:
Connecting Rod Bolt
Torque Procedure:
1. Torque to 24 lb-ft. (33 Nm)
2. Tighten an additional 60°
(see image)

Oil Passage Tube

1. Replace O-rings (A) on both ends of the oil supply tube.
2. Apply a light film of engine oil to O-rings.
3. Push oil tube into upper crankcase.
ENGINE
Install New
Match marks
Marked side of rods
facing same direction
A
5.53
5