Polaris 1999 Sportsman 400 Service Manual page 164

ISH
beari ng until it is fully seated on the bearing
(Figure 75).
NOTE
!fit is difficult to III/screw the threaded
rod
fro m
the crankshaft,
instal l
noVo
nuts onto the threaded rod and tighten
them securely agains t each other.
Using these nuts, unscrew the
threaded rod.
g. Loosen the nut and remove the threaded rod,
washer and collar from the crankshaft.
4B. If the special tools are not available, take the
crankshaft and left side crankcase to a Polaris deal-
ership, or machine shop, and have them properly in-
stall the crankshaft.
5. Place the left crankcase on a couple of wooden
blocks (Figur e 76), or the wooden box used during
separation with the mating surface facing up.
6. If so equipped, install the proper shim (Figure
77) onto the crankshaft. Make sure it is properly
seated (Figure 7H).
7. Rotate the crankshaft so the timing mark (Figure
79) is facing in the direction of the balance shaft.
8. Install the balance shaft part way into the left
crankcase.
CAUTION
Improper alignment of the balance
shaft gear to the crankshaft gear will
result in severe engine vibration lead-
ing to expe nsive engine damage.
9. Rotate the balance gear until the timing mark is
aligne d with the timing mark on the cranksha ft gear
(Figure 80). Push the balance shaft and gear down
until they are fully seated on the bearing. Recheck
the alignment of the timing marks (Figure HI ), re-
adj ust if necessary.
10. If so equipped, install the proper shim onto the
balance shaft (Figure 82) make sure it is properly
seated (Figure 83).
11. Fill the oil pump cavity in the crankcase with
clean engine oil (F igure 84).
NOTE
Do not use anygasket sea ler
011
the oil
pump mating
surfaces.
12. Apply a light film of engine oil to the oil pump
and crankcase mounting surface (Figure 85) and in-
stall the oil pump (Figure 86) .
®
C HA PT ER FIVE