Crankshaft Removal / Installation; Crankshaft Inspection - Polaris Outlaw 500 Service Manual

Crankshaft Removal / Installation

To remove crankshaft:
1. Remove the crankshaft retaining nut using Crankshaft Nut
Remover / Installer (PA-46076).
2. Remove the crankshaft bearing retainer screws using a
impact driver at location (A).
NOTE: Screw threads
Heating of screws is required for removal. Use
caution and wear the proper safety equipment while
performing this procedure.
PTO side shown for clarity
A
3. Support the stator side crankcase in a stand to press the
crankshaft out. Use care not to damage the crankcase
mating surface or connecting rod. Applying heat to the
crankcase bearing area to ease removal is acceptable.
4. Attach Crankcase Separator (PA-46087) to the casehalve.
Turn the inner shaft clockwise while holding the outer shaft
to press the crankshaft and bearing as an assembly out of
the case.
PA-46087
To install crankshaft:
5. Press the bearing into the crankcase at the outer edges with
an appropriate driver. Insert the bearing retainers and new
screws, which have a pre-applied locking agent. Torque the
screws to 8.1–9.6 ft. lbs. (11–13 Nm).
contain locking agent.
Verify that all bolts are
fully threaded to avoid
damage to the case
6. Using MAG End Crankshaft Installer (PA-46077), draw
the crankshaft into the bearing assembly by sliding the
collar and thrustwasher over the crankshaft end, threading
the inner puller onto the crankshaft end. Turn the outer nut
clockwise while holding the inner to pull the crankshaft into
the bearing.
PA-46077
Inner Puller
Outer Puller
Thrust Washer
Collar

Crankshaft Inspection

NOTE: Larger than standard readings indicate
excessive wear.
NOTE: Crankshaft components are press-fit and are
serviceable.
1. Inspect the crankshaft connecting rod bearing journal for
scoring and abnormal wear.
2. Use a feeler gauge to measure the connecting rod big end
side clearance.
Connecting Rod Big End Side Clearance:
Limit: .0256
ENGINE
"
(.65 mm)
3.29
3