Oil Pump Removal/Disassembly; Oil Pump Inspection - Polaris 1999 Sportsman 400 Service Manual

168
a
=
(b
+
c) - (d
+
e)
a = the new shim thickn ess.
b
=
the distance recorded in Step 4 .
c
=
the distance from the top of the stra ightedge to
oi l pum p mo unting surface in the right cra nkcase
half (Step 5).
d
=
the distan ce from the mat ing surface of the oil
pump to the top surface of the gear (Step 6).
e
=
the specified end play in Table 2.
OIL P UMP
T he cran kca se must be separated to acce ss the oil
pump assembly.
There are two chambers in the oil pump ; one is the
feed side (thin rotors) and the other is the side
(thicker rotors). The specification listed in Ta ble 2
relates to the rotors in both chambers.
Rem ovat/Di sas scmbly
Refer to Figure 123 .
I. Sepa rate the crankcase halves as described
111
this chapter.
2. Remove the bolt s (A. Figur e 124) securing the
oil pump and remove the o il pump (B. Figure 124)
from the righ t crankcase half.
3. Remove the three screws attaching the pum p in-
take screen and remove the screen from the pump
(Figu re 125) .
4 . Remove the screw sec uring the feed chamber
cover and rem ove the cover (Figure 126) from the
m iddl e cover.
5. Inspect the feed chamber components as de-
scribed in the foll owin g procedure .
6. Remove the feed chamber inner and outer rotors
and dowe l pin (A. Figure 127).
7. Remove the midd le cover ( B. Figu re 127) from
the oi l pump body ,
8. Inspect the scavenge chambe r components as
desc ribed in the follow ing proc edure.
9. Remove the sca venge chamber inner and outer
rotors and dowel pin (A. Figure 128) from oi l pump
bod y (B. Figure 128).
10. Inspect a ll co mponents as described in the fol-
lowin g procedure.
CHAPTE R FIVE
Inspection
Refer to the serv ice limi t dim ension listed in Ta -
hi e 2. Repl ace wo rn or damaged part s. If several
part s req uire replacement,
it
is reco mmended that
the entire oil pump be repl aced .
I.
C lean an d inspect the scree n ( Fig u re 129 ).
Check for damage to the scree n and for othe r da m -
age indi cated by meta l panicl es in the sc reen.
2. Check the clearance of the
feed side
rotors as
follo ws :
a. Use a feeler ga uge to measure the clea rance
betwee n the o uter rotor and the mid d le
cover. as shown in Figure 130 .
b. Use a fee ler gauge and measure the clear-
an ce between the tip of the inner rotor and
the oute r rotor as
show n in Figure 131.
c. Use a stra ightedge and feeler gauge across
the m iddle cover as shown in Figure 132 and
measure the end play of the feed pump ro-
tors.
3. Rem ove the feed side inner rotor , ou ter rotor,
dowel pin and middle cover from th e oil pump
body. Keep these part s togeth er as a se t; do not in-
term ix them with scav enge rotors.
4. Check the clearance of the ~('m 'ellge
side
rotors
as follow s:
a. Use a feeler ga uge to measure the clea rance
between the outer rotor and the oil pump
bod y as shown in Figure 133.
b. Usc a feeler gauge an d mea sure the cle ar-
ance between the tip of the inne r rotor an d
the o uter roto r as show n in Figure 134.
c. Use a stra ig htedg e a nd feeler ga uge across
the o il pump bo dy and mea sure th e e nd play
of th e sca venge pump ro tor s as shown in
Figure 135.