Crankshaft Removal/Inspection - Polaris Sportsman 400 Service Manual

CRANKSHAFT REMOVAL/INSPECTION

1. Remove the shim washer from the crankshaft.
2. Support the PTO side crankcase and crankshaft;
press the crankshaft out. Be careful not to damage
the crankcase mating surface or connecting rod.
3. Use a feeler gauge to measure the connecting rod big
end side clearance.
Connecting Rod Big End Side Clearance:
Std: .0039-.0256I (.1-.65 mm)
Limit: .0315I (.80 mm)
4. Place the crankshaft in a truing stand or V-blocks and
measure the runout on both ends with a dial indicator.
Max Runout: .0024" (.06 mm)
5. Measure the connecting rod big end radial clearance.
Big End Radial Clearance:
Std: .0004-.0015I (.011-.038 mm)
Limit: .0020I (.05 mm)
6. Inspect the crankshaft main bearing journals for
scoring and abnormal wear.
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