Crankshaft Inspection - Polaris Trail Boss 330 2003 Service Manual

ENGINE
2. Use a feeler gauge to measure the connecting rod
big end side clearance.
Connecting Rod Big End Side Clearance:
Std: .0028-.0118 (0.07-0.30 mm)
Limit: .0138 (.35 mm)
3. If the clearance exceeds the service limit, either
the crankshaft, connecting rod or both need to be
replaced. Refer to Steps 1 & 2 under crankshaft
inspection to determine which part(s) are outside
of specifications.
NOTE: Markings on connecting rod and cap that
must be aligned for assembly. If marks are not clearly
visible, mark the rod and cap with a permanent
marker.
4. Remove the connecting rod nuts and connecting
rod bearing cap.
NOTE: It may be necessary to lightly tap on the side
of the cap with a plastic mallet to loosen it.

CRANKSHAFT INSPECTION

1. Measure the width of the rod bearing journal.
3.30
2. Measure the width of the connecting rod at the big
end.
Connecting Rod Width:
Std: .8233-.8252I (20.88-20.93 mm)
3. Visually inspect bearing journal for scoring,
damage or excessive wear. Replace crankshaft if
it fails visual inspection.
4. Measure the O.D. of the crankshaft rod journal in
four places and in two directions away from the oil
hole. Replace the crankshaft if it measures below
the service limit, or if the journal is out of round.
Rod Bearing Journal O.D.:
Std: 1.6556-1.6560I (41.989-42.000 mm)
5. Check oil passage to make sure it is clear.
Oil passage