Engine Reassembly; Crankcase Reassembly - Polaris Outlaw 500 Service Manual

ENGINE
3. Place the crankshaft in a truing stand or V–blocks and
measure the runout on both ends with a dial indicator. See
Crankshaft Straightening on Page 3.10.
Max Runout: .0012
4. Measure the connecting rod big end radial clearance.
Big End Radial Clearance:
Limit: .0004- .0015
5. Measure the connecting rod small end radial clearance.
Small End Radial Clearance:
Limit: .0020
6. Measure the connecting rod small end I.D.
Small End I.D. :
Std: .9058- .9063

ENGINE REASSEMBLY

Crankcase Reassembly

1. Apply a thin layer of Crankcase Sealer (PN 2871557) to all
sealing surfaces of the PTO case half, being careful not to
over apply, as excessive sealant may clog oil passages or
drip into the crankcase. Allow the sealer to set for a few
minutes before assembling the two halves together.
2. Align the crankshaft and balancer timing marks and insert
the components into the stator-side case halve. Then install
the oil tube and transmission assemblies.
3.30
"
(.03 mm)
"
(.011- .038 mm)
"
(.05 mm)
"
(23.007- 23.020 mm)
3. Reassemble the crankcase
accomplished with the stator side casehalve settled in a
suitable fixture that allows it to lay flat. This allows easier
installation without parts falling out of position. Make sure
the oil gallery tube is oriented correctly and the balancer
shaft groove aligns with the water pump shaft. Refer to
photos.
NOTE: Some light tapping with a soft faced mallet
may be required to bring the casehalves together. If
for any reason the cases fail to mate, DO NOT
FORCE. Reverify the transmission assemblies are
fully seated in their respective case half and are not
binding.
Align balancer
shaft and water
pump shaft grooves
Verify pin is aligned with notch in case
4. Reinstall the (12) stator side and (1) clutch side flange bolts,
tightening in a criss-cross pattern. Stop occasionally and
check that all rotating assemblies turn freely. Torque the
flange bolts to 80–97 in. lbs. (9–11 Nm).
halves. This is best
Pin
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