Crankshaft, Counter Balancer And Oil Pump Installation; To Assemble The Crankcase - Polaris Magnum 2x4 Service Manual

Assembly, Cont.
Crankshaft, Counter Balancer, and Oil Pump Installation
ENGINE
EH42PLJEHSOPL Engine
Lubricate all bearings with clean engine oil before assembly. See engine disassembly photos (page 3.43-3.73)
for reference.
Use the crankshaft installation tool kit PN 2871283 to prevent damage to the crankshaft and main bearings during
installation.
1. Install the crankshaft into the PTa side crankcase. Screw the threaded rod into the crankshaft until the
threads are engaged a minimum of one inch (25.4mm).
2. Install the collar, washer, and nut onto the threaded rod. Hold the crankshaft and tighten the nut to draw the
crankshaft into the main bearings until fully seated. Loosen the nut and remove the threaded rod from the
crankshaft. If removal is difficult, install two nuts on the end of the threaded rod and tighten against each other.
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3. Install the proper shim on the magneto end of the crankshaft.
4. Place the balancer shaft in the PTa crankcase aligning the timing marks on the crankshaft and balancer
gears. Install the proper shim washer on the shaft.
5. Inspect the oil pump sealing surface on the crankcase. Apply a light film of engine oil to the surface and install
the oil pump.
NOTE: Do not use gasket sealer on the pump mating surfaces.
6. Align the drive gear with the drive pin on the pump shaft and install the gear. Be sure the gear is fully seated
and properly engaged.
7. Install the proper shim washer on the pump shaft.
Crankcase Assembly
1. Apply 3 Bond 1215 (PIN 2871557) to the crankcase mating surfaces. Be sure the alignment pins are in place.
2. Set the crankcase in position carefully to avoid damaging the pump shaft seal, and install the magneto end
crankshaft installation tool (follow instructions provided with tool kit PN 2871283). Draw the crankcase halves
together by tightening the nut on the tool and tapping lightly in the pump shaft area with a soft faced hammer to
maintain alignment. Continually check alignment of the cases during installation, closing the gap equally until
the surfaces are tightly seated.
3. Remove the tool.
4. Install the crankcase flange bolts and tighten in 3 steps in a criss-cross pattern to specified torque.
Polaris Industries Inc. 3.77
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