Lower Crankcase Preparation; Crankcase Assembly - Polaris GENERAL 2016 Service Manual

ENGINE / COOLING SYSTEM
3. Apply Polaris PS-4 engine oil to both balance shaft
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4. Rotate the crankshaft until the alignment dot
the crankshaft MAG end gear is visible.
5. Install the balance shaft, placing the tooth with the
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alignment dot in-line with the dot on the crankshaft
gear (see reference images below).

LOWER CRANKCASE PREPARATION

NOTICE
Always replace plain bearings when the crankcase or
connecting rods have been disassembled. Refer to
bearing selection procedures.
1. Remove all traces of crankcase sealant from the
crankcase mating surfaces. Inspect the surfaces
closely for nicks, burrs or damage.
2. Clean bolt hole threads to remove any oil or
crankcase sealant.
3. Inspect crankcase bearing bores. Replace the
crankcase assembly if a bearing bore is galled or if
bearing inserts have rotated in the case.
4. Be sure alignment pins are in place where used.
3.68
5. Refer to Engine Oil Flow Chartpage 3.34 at the
beginning of this chapter and trace the oil paths
through the crankcase and cylinder.
6. Flush all oil passages with solvent and then warm
soapy water. Rinse with clear, warm water and dry
with compressed air.
7. Be sure passages are clean and dry before
assembling the crankcase.

CRANKCASE ASSEMBLY

1. Check to be sure the PTO crankshaft seal is resting
properly in the upper crankcase.
2. Align tab of new main bearings
shaft bearings
of the lower crankcase. Press bearing inserts firmly
e into place.
on
3. Apply Polaris PS-4 engine oil to the new bearings
installed in the lower crankcase half.
4. Clean crankcase mating surfaces to remove any oil.
5. Apply a thin, continuous film of Crankcase Sealant
(PN 2871557) to upper crankcase mating surface
as shown. Do not allow sealant to dry before
assembly.
DO NOT block oil passages
9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual
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and new balance
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with the slot in each bearing bore
NOTICE
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with crankcase sealant.
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