Lower Crankcase Preparation; Crankcase Assembly - Polaris RANGER XP 900 2018-2019 Service Manual

ENGINE / COOLING / HVAC SYSTEM

LOWER CRANKCASE PREPARATION

IMPORTANT
Always replace plain bearings when the crankcase or
connecting rods have been disassembled. Refer to the
bearing selection chart provided in the "Crankshaft
Main Bearing Selection"page 3.65 and "Connecting
Rod Bearing Selection"page 3.65 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.
5. Refer to "Engine Oil Flow Chart"page 3.30 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 (A) and new balance
shaft bearings (B) with the slot in each bearing bore
of the lower crankcase. Press bearing inserts firmly
into place.
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.
3.74
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.
IMPORTANT
DO NOT block oil passages with crankcase sealant.
6. Carefully place lower crankcase on upper case,
making sure the oil pump drive chain is fed through
the lower crankcase.
7. Tap lower crankcase with a rubber hammer to seat
the case halves together.
8. Inspect crankcase mating surfaces to be sure they
are joined properly. Investigate the cause of any
gaps.
9929399 R01 - 2018-2019 RANGER XP/ CREW 900/1000 Service Manual
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