Connecting Rod (Big End) Bearing Inspection; Piston Pin / Needle Bearing Inspection; Connecting Rod Small End Inspection - Polaris 2003 Pro X Service Manual

Connecting Rod (Big End) Bearing Inspection

1. Measure connecting rod big end side clearance with
a feeler gauge. Clearance should be equal on all
rods (within .002 ). Rotate rod on crankshaft and
check for rough spots. Check radial end play in rod
by supporting rod against one thrust washer and
alternately applying up and down pressure.
Replace bearing, pin, and thrust washers if side
clearance is excessive or if there is any up and down
movement detectable in the big end bearing.
NOTE: Specialized equipment and a sound knowledge
of crankshaft repair and straightening is required to per-
form crankshaft work safely and correctly. Crankshaft
repair should be performed by trained Polaris service
technicians in a properly equipped shop.

Piston Pin / Needle Bearing Inspection

1. Clean needle bearing in solvent and dry with
compressed air.
2. Inspect needle cage carefully for cracks or shiny
spots which indicate wear. Replace needle bearings
if worn or cracked, and always replace them if piston
damage has occurred.
3. Visually inspect piston pin for damage, discoloration,
or wear. Run your fingernail along the length of the
pin and replace it if any rough spots, galling or wear is
detected.

Connecting Rod Small End Inspection

1. Clean small end of connecting rod and inspect inner
bore with a magnifying glass. Look for any surface
irregularities including pitting, wear, or dents.
2. Run your fingernail around the inside of the rod and
check for rough spots, galling, or wear.
3. Oil and install needle bearing and pin in connecting
rod. Rotate pin slowly and check for rough spots or
any resistance to movement. Slide pin back and
forth through bearing while rotating and check for
rough spots.
4. With pin and bearing centered in rod, twist ends back
and forth in all directions to check for excessive axial
play. Pull up and down evenly on both ends of pin to
check for radial play. Replace pin and bearing if there
is any resistance to rotation or excessive axial or
radial movement. If play or roughness is evident with
a new pin and bearing, replace the connecting rod.
ENGINE
2.49