Crankcase Disassembly (Upper); Piston / Connecting Rod Removal - Polaris Sportsman 850 Service Manual

5. Rotate pump gear until rotors are positioned as
shown below. Use a feeler gauge to measure tip
clearance. .
MEASUREMENT
Clearance should not exceed 0.006" (.15 mm)
6. Measure pump rotor clearance to pump cover plate
with a feeler gauge through the pump outlet window
and compare to specification.
MEASUREMENT
Pump to Cover Clearance:
0.0010–0.0027" (0.025–0.070 mm)
7. Measure shaft axial (end) free play with a dial
indicator and compare to specification.
MEASUREMENT
Axial Play:
0.010–0.030" (0.24–0.82 mm)
8. Inspect inner rotor drive pin for wear or damage.
ENGINE / COOLING SYSTEM
9. Remove oil pressure relief from crankcase. Replace
if debris has entered, or if oil pressure was outside of
specified range.
TORQUE
Oil Pressure Relief Valve:
20 ft-lbs (27 Nm)

CRANKCASE DISASSEMBLY (UPPER)

1. Remove the oil passage connecting tube with O-
rings.
2. Note connecting rod and cap marks so they can be
oriented properly and assembled in the same
manner as matched sets on proper rod journal
New rods can be installed with marks to front or rear.
Rods have no offset.
3. Remove the two connecting rod bolts

PISTON / CONNECTING ROD REMOVAL

1. Piston assemblies can be installed in either
orientation as each piston is symmetric.
NOTE
Replacement pistons can be installed in either
orientation as they are symmetric.
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