Polaris 1999 Sportsman 400 Service Manual page 167

ENGINE LOWER END
161
0 0 0
ami investigate
the
calise of
the
;111el'-
fe re nce . Check 'he shafts and gears
lor proper
installation. Crankcase
halv es are a matched set and are vcry'
expens ive. Do
11 0 1
risk datnug e hy try -
ing
(0
force them together.
CAUTION
The special crankshaft installation
1 001 set (Fig ure 93) (pa rt Na.
287/283)
is
required
10
1'1111 the
cra nksh aft into the right crankcase
half bearing. Do
Hoi try
to pull the
crankshaft ;111 0 the hearing hy l apping
0 11
the right crankcase as the crank-
case and the cranksha ft will be dam-
aged and misaligned.
20A. If usin g the special tool se t, perform the fo l-
low ing:
a. Insta ll the thread ed stud (Figu re 94 ) o nto the
crankshaft. Sc rew
it
on until
it
stops and
tighten
it
sec urely. Do
110t
ove rtighten.
b. Position the right cra nkcase hal f on to the left
crankca se assembly and a lign the locati ng
do wels (Figu re 95) .
c. Install the adapter, was her and nul o nto the
thr eaded stud on the crankshaft (F igure 96) .
d. Slow ly tighten the nut w ith a wre nc h ( Fig ur e
97 ) and pull the crankshaft through the right
side ma in bearing. Make sure the case halves
are parallel to eac h o ther (Figu re 98 ).
c. Gently tap the ea se around the wate r pump to
fully seat the eas e halves (F ig u re 99 ).
f.
If
it
is necessary to j oin both halves. car efull y
tap them toge ther lightly with a plastic or
soft- faced
mallet- do
not use a meta l ham -
mer, as
it
w ill damage the cases.