Engine Lower Assembly - Polaris SPORTSMAN 600 2003 Service Manual

ENGINE ENGINE
Journal O.D.'s
A
Camshaft Journal O.D. :
A. (Mag): 1.654" ± .00039" (42 ± .010 mm)
B. (Ctr.): 1.634" ± .00039" (41.50 ± .010 mm)
C. (PTO): 1.614" ± .00039" (41 ± .010 mm)
5. Measure ID of camshaft journal bores.
Camshaft Journal Bore I.D.:
(Mag): 1.656" ± 0.00039" (42.07 ± 0.010 mm)
(Ctr.) 1.637" ± 0.00039" (41.58 ± 0.010 mm)
(PTO) 1.617" ± 0.00039" (41.07 ± 0.010 mm)
6. Calculate oil clearance by subtracting journal
O.D.'s from journal bore I.D.'s.
specifications.
Camshaft Oil Clearance:
Std: 0.00118" (.0299mm)
Limit: .0039" (.10 mm)
NOTE: Replace camshaft if damaged or if any part
is worn past the service limit.
NOTE: Replace engine block if camshaft journal
bores are damaged or worn excessively.
C
B
Compare to
ENGINE LOWER
REASSEMBLY
WARNING: After any reassembly or
rebuild, the engine must be primed using
the Oil Priming Adapter (PU- - 45778) and
a 3/4- -full oil filter before initial start- -up.
Follow Steps 44- - 45 in this section to
properly prime the engine and to help aid
proper engine break in.
NOTE: Before assembly, clean the bolts and bolt
holes with Primer N (PN 2870585) to remove any
debris. This will ensure proper sealing when installing
bolts and new Loctitet.
1. Install oil pick up (A), if removed. Apply LocTitet
271 (PN 2871954). Torque bolt to 4.5-5.5 ft. lbs.
(6-7 Nm).
2. Install oil baffle weldment (B). Apply LocTitet
262 (PN 2871952). Torque bolts to 4.5-5.5 ft. lbs.
(6-7 Nm).
Oil Baffle Weldment Bolt Torque:
4.5-5.5 ft. lbs. (6-7 Nm)
Oil Pick Up Bolt Torque:
4.5-5.5 ft. lbs. (6-7 Nm)
3. Install the balance shaft. Inspect balance shaft
clearance (C) in both gearcase halves. Rotate
B
A
3.45