Crankshaft / Cam Chain Removal; Cam Chain / Sprocket Inspection; Crankcase Inspection - Lower; Crankshaft Inspection - Polaris Sportsman XP 1000 S 2020 Service Manual

ENGINE / COOLING SYSTEM

CRANKSHAFT / CAM CHAIN REMOVAL

1. Remove crankshaft with cam chain and end seals.

CAM CHAIN / SPROCKET INSPECTION

1. Cam chain should be replaced if damage is evident
or if sprockets show visible signs of wear. Inspect
drive and driven sprockets.

CRANKCASE INSPECTION - LOWER

Remove main bearing inserts from lower crankcase half.
Replace crankcase assembly if a bearing bore is galled
or if bearing inserts have rotated in the case.

CRANKSHAFT INSPECTION

1. Visually inspect surface of crankshaft main and
connecting rod journals. Replace crankshaft if any
journal is scratched or pitted.
3.58
2. Measure each main journal (A) and rod journal (B) in
two locations, 90
measurements for bearing selection. Calculate the
difference between the two measurements for each
journal to determine concentricity (C). Replace
crankshaft if any journal is worn below the minimum
diameter specification or if journal out-of-round
exceeds maximum specification.
MEASUREMENT
A - Crankshaft Main Journal Diameter:
2.1642 - 2.1650" (54.970 - 54.990 mm)
C - Crankshaft Main Journal Concentricity:
< 0.00027" (0.007 mm) Out Of Round
B - Connecting Rod Journal Diameter:
1.7718 - 1.7726" (45.005 - 45.025 mm)
C - Connecting Rod Journal Concentricity:
< 0.00027" (0.007 mm) Out Of Round
D - Maximum Runout:
.001" (.025 mm)
3. Support crankshaft on V-blocks or on-centers in a
crankshaft stand or lathe. Measure crankshaft runout
(D) and replace if runout exceeds specification
above.
9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
degrees apart. Record
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