Polaris 2005 SPORTSMAN 500 Servise Manual page 100

ENGINE
COUNTER BALANCER
SHAFT END PLAY ADJUST.
Step 2
1. Make sure all bearings are firmly seated in the
crankcase.
2. Measure the width of the counter balancer shaft
at the bearing seats with a dial caliper or
micrometer, and record reading.
Step 3 / 4
3. Measure the distance from the Mag crankcase
mating surface to the balance shaft bearing using
a dial caliper and a straight edge. Subtract the
thickness of the straightedge and record.
4. Measure the distance from the PTO crankcase
mating surface to the bearing using the same
method outlined in Step 1, 2, and-3.
5. Add the readings obtained in Step 3 and Step 4.
6. Subtract the counter balancer shaft width
measured in Step 2 from the figure obtained in Step
5.
7. Subtract the thickness of the existing shim from
the result of Step 6 to determine if a different shim
is needed. The result must be within the specified
range listed at below.
3.40
Counter Balancer Shaft End Play:
.008"-.016" (.02-.04 cm)
OIL PUMP SHAFT END PLAY
ADJUSTMENT
1. Make sure the pump shaft bearing is firmly seated
in the Magneto side crankcase.
2. Measure the distance from the magneto
crankcase mating surface to the bearing using a
dial caliper and a straight edge. Subtract the
thickness of the straightedge and record.
3. Install the gear on the oil pump and measure the
width of the pump and gear. Subtract this
measurement from the measurement recorded in
Step 2.
4. Subtract the thickness of the existing shim from
the result of Step 3 to determine if a different shim
is needed. See Shaft End Play Spec. next page.