Crankcase Assembly - Polaris 1999 Sportsman 400 Service Manual

156
3 .
Pos ition the new sea l as sho wn in Figure 63
and insta ll it o nto the wa ter pu mp shaft. Push
it do wn until it botto ms (A , Figu re 64) .
b. Insta ll the push piece (B , Fi gu re 64) and cen-
ter it o ver the mechan ica l sea l (F igure 65).
c. Screw the threaded shall onto the water pump
sha ft (Figu re 66) and tighten it sec ure ly.
d. Install the tlat washer and nnt (A, Fig ure 67)
and tighten securely.
e . Usc an open- end wren c h ( B, Figu r e 67) to
tighten the nut to press the sea l into the crank-
case bore .
f.
Remove the spec ia l tool and c heck that the
sea l is seated correctly (F ig ure 68) .
Crankcase Assembly
I.
Repl ace the right side oil se al prior to reassem-
bling the case halves.
2. App ly clean en gine oil to all bearing sur fa ces in
bot h case hal ves.
3. Prior to install ing any co mpo ne nts into the
left
crankcase,
perform Shaft End Float Measurement
and Shim Selection
in this cha pte r. Th is w ill deter-
mine the correct thickn ess of shims to install on the
w ater pump shall ,
crankshaft
and bal ance sha ft.
CAUTION
The special crankshaft ills/alia/ion
1001
set (part No.
28 71283)
is re-
qu ired to pull the crankshaft into the
lef t crankcase half bearing. Do not
dri ve the crankshaft into the bearing.
as the crankshaft will be mis aligned.
4A . lf usi ng the special tool set, perform the follow-
ing :
a. Place the
left
crankcase ha lf on wooden
blocks and partially insta ll the cra nkshaft into
the crankc ase bear ing (F ig ure 69) .
b. Make
a
mark
0 11
the thr ea ded rod 25 .4 mill
(1.0 in.) fro m the end (Fig ure 70) .
c. Screw the thr eaded rod into the cranks haft up
to the mark mad e in subste p b (A , Fig u re 71 ).
d. Insta ll the collar (B, Fig u re 71), washer and
nut onto the threaded rod (Figu re 72 ).
c. Ce nter the connec ting rod wi th in the crank-
case openiug (F igure 73 ).
f.
Hold onto the cranksha ft and tighten the nut
(Fig ure 74) to dra w the crankshaft into the
CHAPTER FIVE