2004 Polaris Touring Service Manual, Page 62Get this manual
ENGINE Crankshaft Main Bearing Inspection
Clean crankshaft thoroughly and oil main and connecting rod bearings with Polaris engine oilCarefully check each main bearing on the shaft
NOTE: Due to extremely close tolerances, the bearings must be inspected visually, and by feelLook for signs of
discoloration, scoring or gallingTurn the outer race of each bearingThe bearings should turn smoothly and quietlyThe inner race of each bearing should fit tightly on the crankshaftThe outer race should be firm with minimal side to side movement and no detectable up and down movementReplace any loose or rough bearings
Connecting Rod (Big End) Bearing Inspection
1Measure connecting rod big end side clearance with feeler gauge500600 Liberty Engines should have clearance of (.28 .75mm) and 700800 Liberty Engines should have (.28 .70mm) and be equal on all rods (within .002 )Rotate rod on crankshaft and check for rough spotsCheck radial end play in rod by supporting rod against one thrust washer and alternately applying up and down pressureReplace bearing, pin, and thrust washers if side clearance is excessive or if there is any up and down movement detectable in the big end bearing