Polaris msx 110 Service Manual page 91

ENGINE DISASSEMBLY / ASSEMBLY
Engine Inspection Procedures
Crankshaft Inspection
NOTE: Do not move crankshaft until measurement process is completed. Do not place on oil holes.
Measure crankshaft main bearing clearance.
1. Place upper journal bearings into upper casehalve.
2. Install crankshaft.
across the journal surface. Install lower crankcase
halve with journal bearings installed.
3. Loosely install lower crankcase bolts, turn engine up on
stand.
4. Install old cylinder head gasket, cylinder, and the
cylinder head nuts. Torque nuts and bolts to specified
torque and tightening sequence.
5. Carefully remove components and measure each
compressed piece of Plastigauge .
6. Reference bearing replacement guide if bearing oil
clearance is out of specification.
Out of specification: Replace main bear-
S
ings, crankcase, or crankshaft.
Crankshaft Main Bearing Replacement Guide
Replacement of the crankshaft main bearings is required when the bearing oil clearance is out of specification.
Use this guide to select new bearings.
NOTE: Bearing color code is imprinted on the side of each bearing.
SPECIFIED OIL CLEARANCE: ___________________
MEASURED OIL CLEARANCE: __________________
ORIGINAL INSTALLED BEARING COLOR / THICKNESS: _____________________
REPLACEMENT BEARING THICKNESS
RED .0677 - - .0679 (1.721 - - 1.726mm)
YELLOW .0679 - - .0681 (1.726 - - 1.731mm)
BLUE .0681 - - .0683 (1.731 - - 1.736mm)
GREEN .0683 - - .0685 (1.736 - - 1.741mm)
BROWN .0685 - - .0687 (1.747 - - 1.746mm)
If the measured clearance is within specification, replace with new bearings with the same color code.
If the oil clearance is outside of specification, install the BLUE color--coded bearings and re--measure oil clear-
ance. If the measured clearance is too small, install either a RED or YELLOW bearing. If the measured clearance
is too large, install either a BROWN or GREEN bearing.
If the used bearings reveal an oil clearance of .04 and .05mm, install new bearings with the same color code.
4.36
Place a piece of Plastigauge
.0011" - - .0015" (.03mm - - .04mm)
2004 Four Stroke PWC Service Manual