3.31
Engine/Cooling/Exhaust
3
Disassembly and Assembly Process - Crankcase/
Crankshaft
1. Remove the engine from the engine compartment.
2. Follow the process for removing the cylinder head,
cylinde
rs, pistons, flywheel/recoil housing, and the
water/oil pump.
NOTE: The crankcase ring land damage shown in the
c
orresponding photo is caused by improper
crankcase separation or crankshaft removal.
3. Remove all crankcase fasteners except ones marked
5-
6-7-8 indicated below. Loosen these 4 bolts to
reveal about a 1/6"-1/8" bolt gap.
4. Once loosened, carefully and lightly tap on the bolts
to sepa
rate the crankcase halves.
5. Discard the PTO and MAG crankshaft seals.
6. Remove the crankshaft by pulling
it straight up and
out. Inspect as required.
7. Thoroughly clean the two crankcase mating surfaces
with car
buretor cleaner and a gasket remover. Flush
out the crankcase galleries.
8. Reinstall the crankshaft back into the lower crankcase
usin
g two new crankcase seals.
9. Apply a thin bead of Three Bond 1217H to the lower
cr
ankcase mating surface. Install the upper
crankcase.
NOTE: Do not over-apply sealant in oil injector area.
Do
ing so may block the oil passage.
10. Loosely install the crankcase fasteners, then torque to
th
e specifications at the beginning of the chapter. Use
the correct torque sequence when tightening the
screws.
11. Liberally coat the crankshaft bearings and
com
ponents with Polaris two-stroke engine oil.
800 DC-CFI-2 Crankshaft Identification
Two different crankshaft assemblies (Type 1 and Type 2)
are used for production and service parts. Use the codes
etched into the nose of the PTO end to determine
crankshaft type when ordering service parts.
Type 1 will have the number 3753. Type 2 will have the
nu
mber 0262.
DO NOT FILL MAG
BEARING OIL
GALLERY WITH
CASE SEALANT
DOWELS
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