Polaris Genesis 2000

ENGINE
Disassembly/Inspection - Polaris Engines
Crankshaft Main Bearing Inspection
1 . Clean crankshaft thoroughly and oil main and
connecting rod bearings with Polaris Premium 2
cycle engine oil. Carefully check each main bearing
on the shaft.
NOTE: Due to extremely close tolerances, the bearings
must be inspected visually, and by feel. Look for signs
of discoloration, scoring or galling. Turn the outer race
of each bearing. The bearings should turn smoothly and
quietly. The inner race of each bearing should fit tightly
on the crankshaft. The outer race should be firm with
minimal side to side movement and no detectable up
and down movement. Replace any loose or rough bear
ings.
Connecting Rod (Big End) Side Clearance
1 . Measure connecting rod big end side clearance
with a feeler gauge. Compare to specifications.
Connecting Rod Big End Side Clearance
Standard: .01*- .020*(.3>6-.51mm)
Service Limit: .022" (.56mm)
Connecting Rod (Big End) Radial Clearance
1 . Rotate rod on crankshaft and check for rough spots.
Check radial end play in rod by securing crankshaft
in a holding fixture. Set up a dial indicator as shown
in illustration at right. Support connecting rod
against one thrust washer and apply up and down
pressure on connecting rod. Read total movement
of indicator and compare to specifications. Replace
rod, bearing, pin, and thrust washers if clearance is
excessive. Important Note: A very small amount
of radial play is normal and may be barely
perceptible when inspecting by feel.
Connecting Rbd Big End Radial Clearance
Standard: .0015" - .0018" (.038-.046mm) .
Service Limit: .0021" (.053mm)
Dial
Indicator
O
Connecting
Rod
Crankshaft
NOTE: Specialized equipment and a sound knowledge of crankshaft repair and straightening is required to per
form crankshaft work safely and correctly. Crankshaft repair should be performed by trained Polaris service tech
nicians in a properly equipped shop.
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Polaris Sales Inc.