Polaris 1999 Sportsman 400 Service Manual page 166

160
CHAI'TER FIVE
®
o
13. Install the three bolts and tighten to the torque
speci fication listed in Table
I.
®
14. Align the oil pump drive gea r pin receptacle
(Figu re 87 ) with the raised pin (Figur e 88 ) on the
oil pump shaft and install the dri ve gear (A, Figure
89) . Make sure the drive gear is properly meshed
with the drive pin (Fig ure 90).
uote
When al/ shafts have been correctly
installed in the crankcase, the top sur-
f aces of each mating ge ar will bejlush
with each other (B. Fig ure 89).
15. Install the corre ct shim thick ness for the pump
shaft (C, Fig ure 89) . Make sure it is properly seated
(Figu re 90).
16. Ifrem oved, install the locatin g dowels onto the
Icft crankcase half. Refer to Fig ure 91 and Figure
92 . Make sure they are correctly seated .
17. The crankcase assemblies are now ready to be
joined.
l 8. Make sure both crankcase scaling surfaces are
free of old sealant material or other residue.
19. Apply a light coating of non-hardening liquid
gasket sealer, such as ThreeBond No. 1104, or equiv-
alent, onto the
len
crankcase mating surface. When
selecting an equivalent, avoid thick and hard-setting
f91\
materials. Make sure the coating is as thin as possi-
~
ble, but still completely covering the surface.
CAUTION
When properly lined up. the rig'"
crankcase half will slide
Ol'er
the
shafts and seat against the left case
half/fthe crankcase halves do not fit
together completely. do
1I0t
attempt to
p ull
them together with
the cra nkcase
bolts. Separate the crankcase halves