Engine Reassembly; Crankcase Reassembly - Polaris 2011 RANGER RZR Service Manual

4. Measure camshaft journal outside diameters (O.D.).
A
Camshaft Journal O.D.
A. (MAG) 1.654" ± .00039" (42 ± .010 mm)
B. (CTR) 1.634" ± .00039" (41.50 ± .010 mm)
C. (PTO) 1.614" ± .00039" (41 ± .010 mm)
5. Measure ID of camshaft journal bores.
Camshaft Journal Bore I.D.
MAG: 1.656" ± 0.00039" (42.07± 0.010 mm)
CTR: 1.637" ± 0.00039" (41.58 ± 0.010 mm)
PTO: 1.617" ± 0.00039" (41.07 ± 0.010 mm)
6. Calculate oil clearance by subtracting journal O.D.s from
journal bore I.D.s. Compare to specification.
Calculated Camshaft Oil Clearance:
Std: 0.0027" (.070 mm)
Limit: .0039" (.10 mm)
NOTE: Replace camshaft if damaged or if any part is
worn past the service limit.
NOTE: Replace the engine crankcase assembly if
camshaft journal bores are damaged or worn
excessively.
C
B
= In. / mm.
= In. / mm.
= In. / mm.
9923142 - 2011 RANGER RZR / RZR S / RZR 4 Service Manual
© Copyright 2010 Polaris Sales Inc.

ENGINE REASSEMBLY

Crankcase Reassembly

CAUTION
After any reassembly or rebuild, the engine
must be primed using the Oil Priming Adapter
(PU-45778) and a 3/4-full oil filter before initial
start-up (see "Oil Pump Priming").
NOTE: Before assembly, clean the bolts and bolt
holes with Primer N (PN 2874275) to remove any
debris. This will ensure proper sealing when
installing bolts.
1. Install oil pick up (A), if removed. Torque to specification.
2. Install oil baffle weldment (B). Torque bolts to
specification.
Oil Baffle Weldment & Oil Pick Up Bolt Torque:
60 ± 6 in. lbs. (6.8 ± 0.68 Nm)
3. Install the balance shaft. Inspect balance shaft clearance (C)
in both gearcase halves. Rotate balance shaft to ensure there
is clearance between it and the oil baffle weldment.
ENGINE
B
A
= T
C
3.47
3