ENGINE
2.39
Assembly, Cont.
4. If studs were removed or new crankcase installed,
apply Loctite¥ 242 to threads of studs and screw in
until bottomed. Tighten securely.
5. Measure installed length of stud bolt. This is the
length necessary to allow cylinder installation.
6. Install crankcase halves together. Torque bottom
crankcase bolt to specification in the proper
sequence found in the beginning of this chapter.
7. Install new O-rings on water manifold. Grease
O-rings and install manifold.
8. Lubricate main bearing oil holes with Polaris
Premium 2 Cycle or Premium Gold engine oil
and rotate crankshaft to distribute oil evenly.
9. Install a new C-clip in both pistons (inside) with
gap facing up or down. Be sure clip is fully
seated in the piston groove.
Lower Crankcase Stud Height
121-124 mm (4.76-4.88s) from crankshaft
parting line.
Replace O-rings
Gap Up
Gap Down
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