5.30
Engine and Cooling Systems
Disassembly / Assembly Process - 2008 800 CFI
Crankcase / Crankshaft
1. Remove the engine from the engine compartment.
2. Follow the process for removing the cylinder head,
cylinders, pistons, flywheel / recoil housing, and the water
/ oil pump.
3. Remove the intake boots, reed stuffers, and reed assemblies
from the intake tracks. Discard any seals or gaskets.
4. Remove the fasteners from the bottom of the crankcase.
Carefully pry apart the crankcase halves. Discard the PTO
and MAG crankshaft seals.
5. Remove the crankshaft. Inspect as required.
6. Thoroughly clean the two crankcase mating surfaces with
carburetor cleaner and a gasket remover. Flush out the
crankcase galleries.
7. Reinstall the crankshaft back into the lower crankcase using
two new crankcase seals.
8. Apply a thin bead of Three Bond 1215 to the lower
crankcase mating surface. Install the upper crankcase.
9. Loosely install the crankcase fasteners, then torque to the
specifications at the beginning of the chapter. Use the
correct torque sequence when tightening the screws.
10. Liberally coat the crankshaft bearings and components with
Polaris two-stroke engine oil.
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