Break-In Procedure; General Engine Specifications; Engine Lubrication System - Polaris 1999 Sportsman 400 Service Manual

134
6. Install the ca msha fi chain into the lower port ion
of the crankcase and engage the camshaft chain
onto
the dr
ive sproc ket
(B,
Figure
150).
7. Tie a piece
of w ire
to the camshaft chainandpull
it up through the cha in tunnel in the
cylinder
block
and
cylinder
hcad.
8. Insta ll the dr iven sprocke t onto the chain and se-
cure the upperend
o f the
chain and driven sprocket
to the exterior of the engine.
9.
Install the rear tcnsioner slider down through the
top of the chain tunn el in the cylinder head and cyl-
inder block .
10. Install the bo lt (Fig ure 149) sec uring the cam-
shaft chain rear tensioner slider to the crankca se.
Tighten to the torqu e spcc ifieation listed in Ta b le 3 .
I
I.
Install the alternator stator pla te and flywheel
as described in this chapter.
12. Install the recoil starter assemb ly as de scribed
in this chapter.
13. Install thc cam sha ft as described in this chapter.
14. Install rocker arm assembly and the cylinder
head cover as described in this chapter.
Normal wea r
CHA PTE R FOUR
Excessive wear
BREA K - IN I'IWCED URE
Ift he piston rings were replaced, a new piston in-
sta lled, the cy lind er rehored or hon ed, bre ak the en-
gine in as though it were
new.
The
performance
and
service life
of the
engine depends greatly on a care-
ful
and sensible brea k-in.
For the first 5- 10 hours of opera tion, lise no more
than 113 thro ttle, and vary the speed as much as po s-
sible w ithin the 1/3 thrott le limit. Avo id hard accel-
eration in addition to prolonged steady running at
one speed, no matter how moderate.
After the initial 5- 1() hours of operation, use pro-
gress ively more throttle with short bursts of speed
until the ATV has run for 10- I5 hours.
Item
Engine type
Coo ling system
Bore and stroke
Displacement
Comp res sion ratio
Item
Dry sump
Engine oil
Typ e
Viscosity
011 c apacity
Oil pressure at 5500 rpm
Standard
Minimum
Table 1 GENERAL ENGI NE SPECIFICATIONS
Specifications
Four-stroke, SOHC , single cylinder
Liquid
92
x
75
mm
(3.622
x
2.953
In.)
498
cc
10
to
1
Table 2 ENG INE LUBRICAT ION SYSTEM
Specification
SE or SF
Polaris Premium 4 Synthetic 10W/40
or SAE 10W/40 motor all
1.89
L (2 U.S.
qts.)
138
kPa (20 p si)
83
kPa (12 psi )