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Engine
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ENGINE
CHAPTER 3 ENGINE
GENERAL INFORMATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.2 ENGINE SERVICE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 ENGINE EXHAUST SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.6 INTAKE AIRBOX . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.7 ENGINE REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8
ENGINE REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.8 ENGINE INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.11 ENGINE MOUNT REPLACEMENT . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.15
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ENGINE SPECIFICATIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.3 TORQUE VALUES / ENGINE LUBRICATION SPECIFICATIONS . . . . . . . . . . . . . . . . . 3.5
ENGINE LUBRICATION SYSTEM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16
CYLINDER HEAD . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19
INTAKE MANIFOLD / VALVE COVER REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19 GLOW PLUGS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19 CYLINDER HEAD REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.19 ROCKER ARMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.20 INTAKE AND EXHAUST VALVES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.21 CYLINDER HEAD - SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.23 VALVE SPRING INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.25 ROCKER ARM / PUSH ROD INSPECTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.26 VALVE TAPPET INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27 CYLINDER HEAD ASSEMBLY . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.27 VALVE CLEARANCE INSPECTION / ADJUSTMENT . . . . . . . . . . . . . . . . . . . . . . . . . . 3.29 CYLINDER HEAD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.30 INTAKE MANIFOLD / VALVE COVER ASSEMBLY. . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
CAMSHAFT AND TIMING GEARS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.31
TIMING GEARCASE COVER REMOVAL / INSTALLATION . . . . . . . . . . . . . . . . . . . . . 3.31 TIMING GEARS BACKLASH - CHECKING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.32 IDLER GEAR INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33 TIMING GEARS REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.33 TIMING GEARS INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34 CAMSHAFT REMOVAL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.34 CAMSHAFT INSPECTION / SERVICING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.35 PISTON AND CONNECTING ROD REMOVAL / INSPECTION . . . . . . . . . . . . . . . . . . 3.36 PISTON INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.38 CONNECTING ROD INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.40 CYLINDER HONING AND BORING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41 PISTON AND CONNECTING ROD INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.41 CYLINDER BORE - INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.43 CRANKSHAFT AND BEARINGS REMOVAL. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.44 CRANKSHAFT AND BEARING SERVICE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.45 CRANKSHAFT OIL SEAL REPLACEMENT. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.46 CRANKSHAFT AND BEARINGS INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.47 HAND LEVER REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.49 CABLE REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.50
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CRANKSHAFT AND PISTONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.36
ENGINE SPEED CONTROL . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.49 TROUBLESHOOTING. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.52
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OIL PAN REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16 OIL PUMP REMOVAL AND INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.16 OIL PUMP INSPECTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.17 ENGINE OIL PRESSURE - TESTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3.18
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ENGINE
GENERAL INFORMATION
Special Tools
TOOL DESCRIPTION L1 Valve Guide Tool (for removing valve guides) 0.787 in. (20 mm) L1 Valve Guide Tool (for installing valve guides) 0.394 in. (10 mm) L1 Wrist Pin Bushing Tool 0.984 in. (25 mm) L1 Stem Seal Tool (for installing stem seals) 0.433 in. (11 mm) PART NUMBER / APPLICABLE MODEL AND TOOL SIZE L2 d1 d2 2.953 in. (75 mm) L2 2.362 in. (60 mm) L2 3.346 in. (85 mm) L2 2.559 in. (65 mm) 0.217 in. (5.5 mm) d1 0.433 in. (11 mm) d1 0.866 in. (22 mm) d1 0.374 in. (9.5 mm) d2 0.669 in. (17 mm) d2 0.984 in. (25 mm) d2
0.591 in. (15 mm)
Valve Spring Compressor
Yanmar Part Number: 129100-92630
Piston Ring Compressor (for installing pistons)
Yanmar Part Number: 955500-02476 2.362-4.921 in. (60-125 mm)
SPX Corp: 1-800-328-6657 or http://polaris.spx.com/
Engine Description
The Yanmar 3TNM72 is a vertical, water cooled, 4-cycle, three cylinder diesel engine. A cylinder fires every 240° of crankshaft rotation.
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Flex-Hone (for preparing cylinder walls)
Yanmar Part Number: 129400-92410 2.756-2.992 in. (70-76 mm)
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0.827 in. (21 mm)
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ENGINE SERVICE SPECIFICATIONS
Engine Specifications
Component Height Compression Cylinder Head Intake Valve Recession Exhaust Valve Recession Intake Valve Seat Angle Exhaust Valve Seat Angle Valve Seat Correction Angle Intake Valve Seat Contacting Width Intake Valve (Margin Thickness) Intake Valve Stem O.D. Intake Valve Stem Oil Clearance Intake Valve Length Exhaust Valve Seat Contacting Width Valves Exhaust Valve (Margin Thickness) Exhaust Valve Stem O.D. Exhaust Valve Length Valve Guide I.D. Valve Stem Bend Valve Clearance Valve Spring Exhaust Valve Stem Oil Clearance Measurement Cylinder Mating Surface Warpage Standard 3.855" (97.92 mm) 470 ± 15 PSI (3200 ± 100 kPa) 0.0157 - 0.0236" (0.4 - 0.6 mm) 0.0157 - 0.0236" (0.4 - 0.6 mm) 120° 90° 40°, 150° 0.0028" (0.7 mm) 0.039" (1.0 mm) Service Limit 0.002" (0.05 mm) 370 ± 15 PSI (2600 ± 100 kPa)
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0.0354" (0.9 mm) 0.0315" (0.8 mm) 0.055" (1.4 mm) 0.031" (0.8 mm) 0.2323" (5.9 mm) 0.0063" (0.17 mm) 0.071" (1.8 mm) 0.031" (0.8 mm) 0.2323" (5.9 mm) 0.0067" (0.15 mm) 0.0004" (0.010 mm) 0.512" (1.3 mm) 0.4752" (12.07 mm) 0.4701" (11.94 mm) 0.0051" (0.13 mm) 0.0012" (0.03 mm) 0.8284" (21.041 mm) 0.8231" (20.907 mm) 0.0053" (0.134 mm) 0.002" (0.05 mm) 0.0012" (0.03 mm) 0.0012" (0.03 mm) 0.0024" (0.060 mm) 2.8425" (72.20 mm)
0.2346 - 0.2356" (5.960 - 5.985 mm) 0.0006 - 0.0020" (0.015 - 0.052 mm) 3.976" (101.0 mm) 0.039" (1.0 mm) 0.039" (1.0 mm)
Valve Guide Protrusion Above Head
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0.2342 - 0.2350" (5.945 - 5.970 mm)
0.0012 - 0.0026" (0.030 - 0.067 mm)
3.984" (101.2 mm) 0.2362 - 0.2367" (6.0 - 6.012 mm) 0.3858 - 0.3937" (9.8 - 10.0 mm) -
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0.006 - 0.010" (0.15 - 0.25 mm) 1.4882" (37.8 mm) 0.4724 - 0.4732" (12.00- 12.02 mm) 0.4711 - 0.4718" (11.97 - 11.98 mm) 0.0006 - 0.0021" (0.016 - 0.055 mm) Less than 0.0012" (0.03 mm) 0.8268 - 0.8276" (21 - 21.021 mm) 0.8239 - 0.8252" (20.93 - 20.96 mm) 0.0016 - 0.0037" (0.040 - 0.094 mm) 2.8346 - 2.8358" (72.0 - 72.03 mm) 0.0006 - 0.0020" (0.015 - 0.050 mm) -
Valve Spring Free Length Valve Spring Squareness
Rocker Arms Push Rod Tappet
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Cylinder
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Rocker Arm I.D.
Rocker Shaft O.D. Push Rod Bend
Rocker Shaft Oil Clearance Tappet Bore (Block) I.D.
Tappet Stem O.D.
Oil Clearance Cylinder - Surface Warp (mating with cylinder head)
Cylinder Bore Cylinder Out of Round Limit Cylinder Taper Limit Cylinder to Piston Clearance Cylinder Boring Limit
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Component Measurement Cam Lobe Height (Intake and Exhaust) Gear End Journal Bearing I.D. Gear End Journal O.D Gear End Journal Oil Clearance Camshaft Intermediate Bearing I.D. Intermediate Journal O.D. Intermediate Journal Oil Clearance Flywheel End Journal Bearing I.D. Flywheel End Journal O.D Flywheel End Journal Oil Clearance O.D. Piston to Cylinder Clearance Piston Pin O.D. Pin Bore Diameter Pin Oil Clearance Top Ring Groove Width Top Ring Width Top Ring Side Clearance Top Ring End Clearance Second Ring Width Second Ring Groove Width Piston Rings Standard 1.3596 - 1.3648" (34.54 - 34.67 mm) 1.5748 - 1.5758" (40 - 40.025 mm) 1.5724 - 1.5732" (39.94 - 39.96 mm) 0.0016 - 0.0033" (0.04 - 0.085 mm) 1.5748 - 1.5758" (40 - 40.025 mm) 1.5713 - 1.5722" (39.91 - 39.94 mm) 1.5748 - 1.5758" (40.0 - 40.025 mm) 1.5724 - 1.5732" (39.94 - 39.96 mm) 0.0016 - 0.0033" (0.04 - 0.085 mm) 0.0004 - 0.0028" (0.01 - 0.07 mm) 2.8331 - 2.8343" (71.96 - 71.98 mm) Service Limit 1.3499" (32.287 mm) 1.587" (40.100 mm) 1.5711" (39.906 mm) 0.0061" (0.154 mm) 1.5699" (39.875 mm) 1.5787" (40.10 mm) 1.5699" (39.875 mm)
0.0026 - 0.0045" (0.065 - 0.115 mm) 0.0089" (0.225 mm)
0.8659 - 0.8661" (21.995 - 22.0 mm) 0.8648" (21.965 mm) 0.8661 - 0.8665" (22.0 - 22.009 mm) 0.0 - 0.0006" (0.0 - 0.014 mm) 0.0610 - 0.0618" (1.55 - 1.57 mm) 0.0579 - 0.0587" (1.47 - 1.49 mm) 0.0024 - 0.0039" (0.06 - 0.10 mm) 0.0039 - 0.0098" (0.10 - 0.25 mm) 0.8677" (22.039 mm) 0.0029" (0.074 mm) 0.0622" (1.58 mm) 0.0571" (1.45 mm) Not Applicable 0.0013" (0.034 mm) 0.0667" (1.695 mm) 0.0571" (1.45 mm) 0.0096" (0.245 mm) 0.0193" (0.49 mm) 0.1232" (3.13 mm) 0.1161" (2.95 mm) 0.0071" (0.18 mm) 0.0217" (0.55 mm) 1.1779" (29.919 mm) 0.0059" (0.147 mm) 0.7902" (20.072 mm) 0.0041" (0.105 mm) 0.0043" (0.110 mm) 0.0008" (0.02 mm) 0.0110" (0.28 mm) 0.0728" (1.85 mm) 0.0008" (0.02 mm) 1.4725" (37.402 mm) 0.0043" (0.110 mm)
Second Ring Side Clearance Second Ring End Clearance Oil Ring Groove Width Oil Ring Width
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Oil Ring Side Clearance Oil Ring End Clearance Idle Gear Shaft and Bushing Idle Gear Shaft O.D. Idle Gear Bushing I.D. Small End I.D.
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Idle Gear Bushing Oil Clearance Small End Radial Clearance
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Connecting Rod
Big End Side Clearance Big End Radial Clearance Bend End Play
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0.0622 - 0.0628" (1.58 - 1.595 mm)
0.0579 - 0.0587" (1.47 - 1.49 mm)
0.0035 - 0.0049" (0.09 - 0.125 mm)
0.0098 - 0.0157" (0.25 - 0.40 mm)
0.1185 - 0.1191" (3.010 - 3.025 mm)
0.1170 - 0.1177" (2.97 - 2.99 mm) 0.0008 - 0.0022" (0.02 - 0.055 mm) 0.0079 - 0.0177" (0.20 - 0.45 mm) 1.1795 - 1.1803" (29.96 - 29.98 mm) 0.0008 - 0.0026" (0.02 - 0.066 mm) 0.8671 - 0.8678" (22.03 - 22.04 mm) 0.001 - 0.0019" (0.025 - 0.047 mm) 0.0079 - 0.0157" (0.20 - 0.40 mm) 0.0008 - 0.0023" (0.020 - 0.058 mm) 0.0044 - 0.0098" (0.111 - 0.250 mm) 0.076 - 0.078" (1.93 - 1.98 mm) 0.0004" (0.01 mm) or less 1.4942 - 1.4946" (37.95 - 37.96 mm) 1.4954 - 1.4965" (37.98 - 38.01 mm) 0.0592 - 0.0594" (1.503 - 1.509 mm) 0.0008 - 0.0023" (0.02 - 0.58 mm)
1.1811 - 1.1821" (30.0 - 30.025 mm) 1.1837" (30.066 mm)
Thrust Bearing Thickness
Crankshaft
Roundness
Rod Journal O.D. Rod Bearing I.D. Rod Bearing Insert Thickness Rod Bearing Oil Clearance
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1.5711" (39.906 mm)
0.0061" (0.154 mm)
2.8313" (71.915 mm)
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Component Measurement Engine Oil Pressure (3600 RPM, Engine Hot) Oil Pump Outer Rotor Outside Clearance Outer Rotor Side Clearance Outer Rotor To Inner Rotor Tip Clearance Standard 42 - 64 PSI (289.6 - 441.3 kPa) 0.0039 - 0.0063" (0.10 - 0.16 mm) 0.0019 - 0.0039" (0.05 - 0.10 mm) Service Limit 0.0098" (0.25 mm) 0.0059" (0.15 mm) 0.0063" (0.16 mm)
Torque Values
TORQUE SPECIFICATIONS Fastener Camshaft Pulley Connecting Rod Bolts Glow Plug Main Cap Bolt Ladder Frame Bolt Fuel Nozzle Nut Fuel High Pressure Pipe Nut Fuel Pump Gear Bolt Cylinder Head Bolts Fuel Pump End Nut Flywheel Oil Pump Size 12 mm 7 mm 10 mm 4 mm 9 mm 9 mm
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20 mm 12 mm 8 mm 9 mm
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12 mm 6 mm
10 mm
Engine Lubrication Specifications
IMPORTANT: Use of a non-recommended engine oil may cause serious engine damage.
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Polaris recommends the use of Polaris Diesel Oil (SAE CI4) for this vehicle. Always use the correct viscosity grade based on the ambient temperature expected during operation. See the chart below.
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Oil Capacity * Oil Filter Wrench Oil Filter Oil Type Ambient Temp Range: -25° F to 104° F Oil Type Ambient Temp Range: +5° F to 104° F Oil Type Ambient Temp Range: -25° F to 80° F Oil Pressure (Polaris engine oil at operating temperature)
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Oil Viscosity / Ambient Air Temperature Chart
SAE 10W-30
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SAE 15W-40 Synthetic 5W-40 +80°F +104°F (+27°C) (+40°C)
-25°F (-31°C)
+5°F (-15°C)
*Additional oil may be required after complete engine disassembly. Check level after filling and add as needed.
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ft-lbs (Nm) 12 ft-lbs (16 Nm) 15 in-lbs (2 Nm) 33 ft-lbs (45 Nm) 33 ft-lbs (45 Nm) 37 ft-lbs (50 Nm) 24 ft-lbs (32 Nm) 25 ft-lbs (34 Nm) 42 ft-lbs (57 Nm) 47 ft-lbs (64 Nm) 60 ft-lbs (81 Nm) 7 ft-lbs (11 Nm)
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61 - 69 ft-lbs (83 - 93 Nm)
83 - 90 ft-lbs (113 - 123 Nm)
Approx. 2.75 Quarts (2.6 L) PU-50105 or 2.5" (64 mm) PN 3070131 Synthetic Diesel Engine Oil 5W-40 All-Season (PN 2879832) Diesel Engine Oil 15W-40 Summer (PN 2878473) Diesel Engine Oil 10W-30 Winter (PN 2878474) 8.8 PSI (60.7 kPa) @ 1350 RPM 42 - 64 PSI (290 - 441 kPa) @ 3600 RPM
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ENGINE
ENGINE EXHAUST SYSTEM
Exhaust Removal / Installation
1. Tilt the rear cargo box to the raised position. Remove upper cargo box shock clip and pin. Allow cargo box to rest fully open. 2. Using spring puller PU-45485, remove the two exhaust springs (Item 1) connecting silencer to headpipe. 3 1 Silencer 2 1
Muffler Removal and Installation
1. Raise the cargo box. 2. Remove the springs (Item 1) that secure the muffler (Item 2) to the exhaust pipe (Item 3). 2 1
Headpipe 4
3. Remove the nuts (Item 4) washers (Item 5) and bolts. 5
3. Pull the two rear isolator mounts (Item 2) toward the right side of the vehicle to disengage from frame mounting posts. 4. Pull silencer toward the rear of the vehicle to disengage silencer mounting post from front isolator mount (Item 3). 5. Remove silencer through right side of vehicle frame.
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4. Remove the muffler.
7. Remove the headpipe from the vehicle.
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IMPORTANT: Install new exhaust gaskets and torque all hardware to specification.
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8. To reinstall the exhaust system, reverse the removal steps.
Headpipe Mounting Bolts: 18 ft-lbs (24 Nm)
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6. Remove the six mounting bolts (Item 4) retaining the headpipe to the engine.
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INTAKE AIRBOX
Airbox Housing Removal and Installation
1. Raise the cargo box. 2. Loosen the clamp (Item 1) and remove the hose (Item 2) from the air cleaner housing. 5 5. Remove the two bolts (Item 5) and remove the airbox from the vehicle.
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4. Plug the hoses to prevent dirt and debris from entering the engine.
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3. Loosen the clamp (Item 3) and remove the hose (Item 4) from the air cleaner housing.
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ENGINE REMOVAL / INSTALLATION
Engine Removal
1. Clean the work area. 2. Thoroughly clean the engine and chassis. 2 9. Disconnect the wires (Item 2) from the alternator.
2 Always wear safety glasses and proper shop clothing when performing the procedures in the manual. Failing to do so may lead to possible injury or death. 3. Disconnect the negative (-) battery cable. 4. Drain the engine coolant from the cooling system (see Chapter 5 "Engine Cooling System"). 5. Remove the transmission from the vehicle (see Chapter 9 "Transmission Removal"). 6. Remove the hydrostatic pump (see Chapter 10 "Hydrostatic Pump Removal"). IMPORTANT: DO NOT remove the pressure hoses from the A/C compressor when removing the engine. Removing the pressure hoses requires A/C system recovery and charging. 7. Remove the A/C compressor (if applicable) (see Chapter 6 "Compressor Removal / Installation").
10. Remove the four nuts (Item 3) for the exhaust shield (Item 4).
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4 11. Disconnect the fuel solenoid (Item 5) and glow plug connector (Item 6). 6
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8. Remove the three screws (Item 1) retaining the guard to the frame and remove the shield.
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12. Disconnect the oil pressure sensor (Item 7). 15. Remove the two tie straps (Item 11).
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13. Disconnect the crankshaft position sensor connector (Item 8).
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14. Cut the tie strap (Item 9) and disconnect the coolant temperature sensor (Item 10).
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16. Disconnect the starter wires (Item 12).
17. Loosen the clamp and remove the water pump inlet hose (Item 13).
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18. Remove the coolant hose (Item 14) from the thermostat housing. 19. Loosen the clamp and remove the heater hose. (If equipped) NOTE: Mark installation. the coolant hoses for ease of 22. Remove the bolt (Item 18) securing the ground cable to the engine block.
23. Disconnect the wire harness (Item 19) from the PTO clutch. 16 15
21. Secure chain to the engine lift brackets (Item 17) and apply slight tension with a hoist.
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24. Remove the wire harnesses from the harness clips (Item 20) on the PTO mounting plate.
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20. Loosen the clamps (Item 15) and remove the fuel lines (Item 16). Plug the lines and cap the fittings.
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NOTE: Drain and dispose of the fluids properly.
ENGINE
25. Remove the four bolts (item 21) and PTO shaft (Item 22).
Engine Installation
1. With the help of an assistant, install the engine in the chassis. 2. Leave the engine lift secured to the engine lift brackets (Item 1) with a slight amount of tension applied to aid installation.
22
21
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21
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23
3
1
26. Remove the motor mount bolts (Item 23) from both sides of the engine.
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1
3. Install the motor mount bolts (Item 2) on both sides. Torque bolts to specification.
27. With the help of an assistant, remove the engine from the vehicle.
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2
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Engine Mount to Engine Fastener: 33 ft-lbs (45 Nm) Engine Mount to Frame Fasteners: 22 ft-lbs (30 Nm)
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ENGINE
4. Install the PTO shaft (Item 3) and four PTO shaft bolts (item 4). Torque fasteners to specification. 6. Connect the wire harness (Item 6) to the PTO clutch.
3
4
4
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PTO Shaft to PTO Gearcase Bolts: 20 ft-lbs (27 Nm) 5. Install the wire harnesses into the harness clips (Item 5) on the PTO mounting plate.
7. Install the bolt (Item 7) securing the ground cable to the engine block. Torque bolt to specification.
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5
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EL
Engine Ground Bolt: 54 in-lbs (6 Nm)
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7
6
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ENGINE
8. Remove the plugs from the lines and fittings. Install the fuel lines (Item 8) and tighten the clamps (Item 9). 12. Connect the starter solenoid wire (Item 12) and the B+ starter wire (Item 13). Tighten B+ nut to specification.
9
8 13
12 8
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Starter B+ Cable: 54 in-lbs (6 Nm) 14
3
9. Install the heater hose (if equipped) and tighten the clamp. 10. Install the coolant hose (Item 10) on the thermostat housing.
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11. Install the water pump inlet hose (Item 11) and tighten the clamp.
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10
IN
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11
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13. Install two new tie straps (Item 14).
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ENGINE
14. Connect the coolant temperature sensor (Item 15) and install a new tie strap (Item 16). 17. Connect the fuel solenoid (Item 19) and glow plug connector (Item 20).
15 19 16
15. Connect the crankshaft position sensor connector (Item 17).
18. Install the four nuts (Item 21) retaining the exhaust shield (Item 22). Torque nuts to specification.
17
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21 21
16. Connect the oil pressure sensor (Item 18).
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Exhaust Heat Shield Nuts: 20 ft-lbs (27 Nm)
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20
ENGINE
19. Connect the wires (Item 23) to the alternator.
Engine Mount Replacement
The engine mount consists of a one piece molded design.
23
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1. Remove the existing mount from the engine (see "Engine Removal" and "Engine Installation" for mount locations). 2. Torque fasteners to specification.
20. Install the guard and the three screws (Item 24) retaining the guard to the frame.
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Engine Mount to Engine Fastener: 33 ft-lbs (45 Nm) Engine Mount to Frame Fasteners: 22 ft-lbs (30 Nm)
24
21. Install the A/C compressor (if applicable) (see Chapter 6 "Compressor Removal / Installation").
PR
22. Install the hydrostatic pump (see Chapter 10 "Hydrostatic Pump Removal" and reverse the steps). 23. Install the transmission in to the vehicle and properly torque the engine to transmission fasteners (see Chapter 9 "Transmission Installation").
24. Refill the engine coolant and bleed the system (see Chapter 5 "Engine Cooling System"). 25. Connect the negative (-) battery cable.
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IMPORTANT: DO NOT remove the pressure hoses from the A/C compressor when installing the engine. Removing the pressure hoses requires A/C system recovery and charging.
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ENGINE
ENGINE LUBRICATION SYSTEM
Oil Pan Removal and Installation
1. Remove the engine. 2. Remove the bolts (Item 1) and oil pan (Item 2).
Oil Pump Removal and Installation
The oil pump is located in the front gear case and is driven by the same gear train that drives the camshaft and fuel injection pump. You must remove the front gear case cover to gain access to the oil pump. 1. Remove the water pump. 2. Remove the crank shaft pulley and gear case cover.
5 4
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3
4. Installation: Tighten the bolts to 7 ft-lbs (11 Nm).
1
2
5. Remove the cover (Item 3) and outer rotor (Item 4) from the housing.
4. Installation: Tighten the bolts (Item 3) to 8 ft-lbs (10 Nm).
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3. Remove the bolts (Item 3), pickup tube (Item 4) and O-ring (Item 5).
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3. Remove the bolts (Item 1) and oil pump assembly (Item 2).
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ENGINE
Oil Pump Inspection
1. Clean the lubricating oil pump, pressure regulator valve (Item 1) and rotor inserting portion. Check the parts for wear or flaw. Replace the parts with new ones as needed. 3. Inspect the outside diameter clearance of the outer rotor. To inspect this, insert a feeler gauge between the outer rotor (Item 2) and the lubricating oil pump body (Item 3).
2
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1 NOTE: If any oil pump component clearance exceeds its limit, the oil pump must be replaced as an assembly. 2. Check Outer Rotor Outside Clearance
= In. / mm.
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4. Check Outer Rotor To Inner Rotor Tip Clearance 5. Inspect the tip clearance between the outer and inner rotors. To inspect this, insert a feeler gauge between the inner rotor tooth tip (Item 4) and the outer rotor tooth tip (Item 5), and measure the clearance.
IN
Oil Pump Specifications Outer Rotor Outside Clearance Std: 0.0039 - 0.0063" (0.10 - 0.16 mm) Limit: 0.0098" (0.25 mm)
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Outer Rotor To Inner Rotor Tip Limit: 0.0063" (0.16 mm) 6. Check Outer Rotor Side Clearance
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3 4 5
3
= In. / mm.
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ENGINE
7. Inspect the side clearance between the lubricating oil pump body and the outer rotor. To measure the side clearance, use a straight edge and feeler gauge or a depth micrometer.
Engine Oil Pressure - Testing
1. Remove the oil pressure sender. 2. Install a pressure gauge.
= In. / mm.
Outer Rotor Side Clearance Std: 0.0019 - 0.0039" (0.05 - 0.10 mm) Limit: 0.0059" (0.15 mm) 8. Check Rotor Shaft Clearance
3. Start the engine and run until it is at operating temperature. Engine Oil Pressure Specification Idle Speed (1350 RPM) Allowable Limit: 8.8 PSI (60.7 kPa) At 3600 RPM: 42 - 64 PSI (289.6 - 441.3 kPa)
IN
9. Inspect the rotor shaft clearance. Measure the outside diameter of the rotor shaft (Item 6) and the inside diameter of the cover. Determine the clearance by subtracting the outside diameter of the rotor from the inside diameter of the cover.
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6
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If the oil pressure is less than the allowable limit, check the following items. · Engine Oil Level Low · Oil Pump Defective · Oil Gallery Plugged · Oil Strainer Plugged · Excessive clearance at the Rod & Main Bearings · Oil Pump Relief Valve Stuck
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ENGINE
CYLINDER HEAD
Intake Manifold / Valve Cover Removal
1. Remove the intake manifold bolts (Item 1) and valve cover bolts (Item 2).
Glow Plugs
NOTE: To prevent damage, the glow plugs must be removed from the cylinder head before the cylinder head is removed. 1. Disconnect the glow plug harness (Item 2) from the glow plugs (Item 1).
1
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1 2 1
2
3
2 4 3
5 8
7
6
2. Remove the valve cover / intake manifold (Item 3). Discard gasket (Item 4).
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4. For orientation, the cooling pump end (Item 1) and camshaft side (Item 2) are identified. 5. Remove the high-pressure fuel lines and fuel injectors from the cylinder head. NOTE: Remove and install the high-pressure fuel injection lines as an assembly whenever possible. Disassembling the high-pressure fuel injection lines from the retainers will result in difficult installation.
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3. Remove the exhaust manifold bolts (Item 5) and nuts (Item 6). Remove the exhaust manifold (Item 7) and the exhaust manifold gasket (Item 8).
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2. Remove the glow plugs from the cylinder head.
Cylinder Head Removal
1. Drain coolant from engine into a suitable container. 2. Remove the water pump. 3. Loosen the cylinder head bolts following the sequence shown in.
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ENGINE
6. Remove the cylinder head bolts (Item 3). 2. Remove the rocker arm shaft assembly from the cylinder head. NOTE: Identify the push rods so they can be reinstalled in their original locations. 3. Remove the push rods and identify for reinstallation. 4. Remove the rocker arm shaft alignment set screw (Item 2) from the support. 3 2
3
9 8
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1 5
4
7
Rocker Arms
Removal
IN
1. Remove the bolts (Item 1) that retain the rocker arm shaft supports.
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1
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7. Lift the cylinder head away from the cylinder block. Discard the cylinder head gasket (Item 4). Position the cylinder head on the work bench to prevent damage to the combustion surface.
5. Remove the two snap rings (Item 3). NOTE: The rocker arm shaft fits tightly in the rocker arm supports. Clamp the support in a padded vise. Twist and pull out on the rocker arm shaft to remove. Reverse this process when installing the rocker arm shaft into the supports. 6. Slide the rocker arm shaft (Item 4) out of the rocker arm supports (Item 5), springs (Item 6) and rocker arms (Item 7). NOTE: Mark the rocker arms so they can be reinstalled with the original matching valve and push rod. 7. Remove the valve adjusting screw (Item 8) and lock nut (Item 9) from the rocker arms. Mark parts so they can be reinstalled on the same rocker arm.
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ENGINE
Installation 1. Lubricate the rocker arm shaft. Slide the rocker arm supports, springs and rocker arms onto the shaft. NOTE: Ensure the lubrication holes in the rocker arm shaft are oriented correctly with respect to the rocker arms. NOTE: The rocker arm shaft fits tightly in the rocker arm supports. Clamp the support in a padded vise. Twist and push on the rocker arm shaft to reinstall. 2. Align the hole in the rocker arm shaft and the hole in the rocker arm support. Reinstall the alignment set screw. NOTE: The set screw is located in the center support. 3. Place the rocker arm shaft assembly onto the cylinder head. 4. If removed, reinstall the valve adjusting screws and lock nuts. 5. Align the push rods with their respective rocker arms. 6. Reinstall and tighten the rocker arm shaft retaining bolts to the specified torque. 7. Tighten the rocker arm shaft alignment screw. 8. Adjust the valve clearance.
Intake and Exhaust Valves
Visually inspect the intake and exhaust valves. Replace any valves that are damaged. Valve Stem Diameter Using a micrometer, measure the valve stem near the combustion end and near the opposite end (Item 1).
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1
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Valve Stem Bend
Valve Stem O.D. Intake (Std): 0.2346-0.2356" (5.960-5.985 mm) Exhaust (Std): 0.2341-0.2350" (5.945-5.97 mm) Limit: 0.2323" (5.900 mm)
Place the valve stem on a flat surface. Roll the valve until a gap can be observed between a portion of the valve stem and the surface. Use a feeler gauge to measure the gap
Valve Stem Bend Limit: 0.0004" (0.010 mm)
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= In. / mm. = In. / mm.
3
ENGINE
Valve Recession NOTE: The valve guides must be installed to perform this check. Insert the valves into their original locations and press them down until they are fully seated. Use a depth micrometer to measure the difference between the cylinder head gasket surface and the combustion surface of each exhaust and intake valve. Valve Removal 1. Put the cylinder head on the work bench with the combustion side down. 2. Remove the valve stem cap (Item 1) and keep it with the valve it was installed on. 3. Using the valve spring compressor tool, compress one of the valve springs. 4. Remove the valve keepers (Item 2).
= In. / mm.
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IN
Intake and Exhaust Valve Recession Std: 0.0157 - 0.0236" (0.40 - 0.60 mm) Limit (Intake): 0.0354" (0.90 mm) Limit (Exhaust): 0.0315" (0.80 mm)
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5. Slowly release the tension on the valve spring and remove the spring retainer (Item 3) and valve spring (Item 4). 6. Repeat procedure with all remaining valves. NOTE: If the valves are to be reused, identify them so they can be reinstalled in their original location. 7. Turn the cylinder head so the exhaust port side faces down. Remove the intake and exhaust valves (Item 6) from the cylinder head. 8. Remove the valve stem seals (Item 5).
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ENGINE
Valve Guide Removal NOTE: Removal of valve guides should be postponed until inspection and measurement procedures have been performed. If the valve guides are not within specifications, use a drift pin and hammer to drive the valve guides (Item 1) out of the cylinder head. Cylinder Head Distortion Put the cylinder head flat and inverted (combustion side up) on the bench. Use a straightedge and feeler gauge to measure cylinder head distortion. Measure diagonally and along each side. Record the measurements.
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If distortion exceeds the service limit, resurface or replace the cylinder head. Remove only enough material to make the cylinder head flat, but do not remove more than 0,20 mm (0.008 in). Cylinder Head Distortion Std: 0.0020" (0.05 mm) or less Limit: 0.0059" (0.15 mm)
Cylinder Head - Servicing
Thoroughly clean all components using a non-metallic brush and an appropriate solvent. Each part must be free of carbon, metal filings and other debris.
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NOTE: Any part determined to not meet the service standard or limit before the next service, as determined from the state of current rate of wear, should be replaced even though the part currently meets the service standard limit. NOTE: Mark all valve train components so they can be installed in their original locations
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NOTE: Any part which is found defective as a result of inspection or any part whose measured value does not satisfy the standard or limit must be replaced.
IN
Visually inspect the parts. Replace any parts that are obviously discolored, heavily pitted or otherwise damaged. Discard any parts that do not meet its specified limits.
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= In. / mm.
1
3
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ENGINE
Valve Guide - Checking Visually inspect the valve guides for distortions, scoring or other damage. NOTE: Measure valve guides while they are installed in cylinder head. Use a telescoping gauge and micrometer to measure the inside diameter of the valve guide. Measure in three places and 90° apart. Replace valve guides if not within specification. 2. Coat the valve seat with a thin coat of bluing compound. Install valve and rotate to distribute bluing onto the valve face. The contact pattern should be approximately centered on the valve face (Item 1) and even in width.
3. Visually inspect the valve seat for even contact. Light cutting can be performed by the use of a hand operated cutter.
= In. / mm.
Valve Guide I.D. Std: 0.2362 - 0.2367" (6.000 - 6.012 mm) Valve And Valve Seat Reconditioning
EL
1. Visually inspect all valve faces and valve seats for pitting, distortion, cracking or evidence of overheating. Usually the valves and valve seats can be lapped or ground to return them to serviceable condition. Severely worn or damaged components will require replacement.
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Always check the clearance between the valve and valve guide before grinding or lapping the valve seats. If the clearance exceeds the limit, replace the valve and / or valve guide to bring the clearance within the limit. Roughness or burrs will cause poor seating of a valve. Visually inspect the seating surfaces of each valve and valve seat to determine if lapping or grinding is needed.
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4. Valve seat diameter can be adjusted by top-grinding with a 150° stone to make the seat diameter smaller, and bottom-grinding using a 40° stone to make the seat diameter larger. Once the seat location has been corrected, grind and lap the seat angle (Item 2) to specification. 2
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Intake Exhaust
Seat Angle
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5. Grind the valve face and / or valve seat only enough to return them to serviceable condition. Grinding is needed if the valve and the valve seat do not contact correctly. Check the valve recession after grinding. 6. If the valve or seat require grinding, lap the valve after grinding. Lap the valve face to the valve seat using a mixture of valve lapping compound and engine oil. 7. Be sure to thoroughly wash all parts to remove all grinding powder or compound.
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1 120° 90°
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Valve Spring Inspection
Inspect the valve springs. If damage or corrosion is seen, or if measurements exceed the specified limits, replace the springs. Fractures Check for fractures on the inside and outside portions of the springs. If the valve spring is fractured, replace the valve spring. Corrosion Check for corrosion of spring material caused by oxidation. Squareness Use a flat surface and a square to check each spring for squareness. Free Length Use a caliper to measure the length of the spring.
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Valve Spring Length Std: 1.4882" (37.80 mm)
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Valve Spring Squareness Limit: 0.512" (1.30 mm)
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= In. / mm.
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= In. / mm.
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ENGINE
Rocker Arm / Push Rod Inspection
Rocker Arm Shaft Hole Diameter 1. Use a telescoping gauge and micrometer to measure the inside diameter of all the rocker arm support brackets and the rocker arms. 2. Inspect contact areas (Item 1) for excessive wear or damage. Rocker Arm Shaft Outside Diameter Use a micrometer to measure rocker arm shaft diameter. Measure at each rocker arm location in two directions 90° apart.
1
1
= In. / mm.
Rocker Arm I.D. Std: 0.4724 - 0.4732" (12.00 - 12.20 mm) Limit: 0.4752" (12.07 mm)
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Push Rod Bend Determine if the bend of the push rods is within the specified limit. 1. Place the push rods on a flat inspection block or layout bed.
2. Roll the push rods until a gap can be observed between a portion of the push rod and the surface of the block or layout bed.
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Rocker Shaft O.D. Std: 0.4711 - 0.4718" (11.966 - 11.984 mm) Limit: 0.4701" (11.94 mm)
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= In. / mm.
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ENGINE
3. Use a feeler gauge to measure the gap. 3. Measure the tappet bores in the cylinder block. Record the measurements.
= In. / mm. = In. / mm.
Push Rod Bend Less than 0.0012" (0.03 mm) Tappet Bore I.D. Std: 0.8268 - 0.8276" (21.000 - 21.021 mm) Limit: 0.8284" (21.041 mm)
Valve Tappet Inspection
1. Inspect the tappet contact surfaces for abnormal wear (Item 1). Normal wear will be even as shown in (Item 2). Slight surface defects can be corrected using an oilstone.
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1
Cylinder Head Assembly
Valve Guide Installation
2. Measure the outside diameter of the tappet.
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Tappet O.D. Std: 0.8239 - 0.8252" (20.927 - 20.960 mm) Limit: 0.8231" (20.907 mm)
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= In. / mm.
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9924344 - 2013 BRUTUS / HD / HDPTO Service Manual © Copyright 2013 Polaris Sales Inc.
1
2
1. The valve guides are installed into the cylinder head with an extremely tight press-fit. Before installing the valve guides, place the valve guides in a freezer for at least 20 minutes. This will cause the valve guides to contract, making it easier to install the valve guides in place. 2. Immediately after removing the valve guides from the freezer, insert the valve guides (Item 1) in their proper positions.
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ENGINE
3. Finish installing the valve guides (Item 2) to the proper height (Item 3) using the valve guide installation tool (Item 4). Valve Installation NOTE: Always install new valve stem seals. 1. Oil the lip of the valve stem seal (Item 6). Using the valve stem seal installation tool (Item 5), install a new valve stem seal on each of the valve guides (Item 7).
4
5 3
2
= In. / mm.
Valve Guide Protrusion Above Head 0.3858 - 0.3937" (9.80 - 10.00 mm)
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2. Measure the distance (Item 8) from the cylinder head to valve stem seal to ensure proper clearance (Item 9) between the valve guide and seal.
IN
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3. Put the cylinder head assembly on its exhaust port side. 4. Install all the valves in their proper location in the cylinder head.
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8 9
Valve Stem Seal Protrusion Above Head 0.543" (13.80 mm)
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= In. / mm.
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ENGINE
5. Put the cylinder head on the work bench with the combustion side down to install the valve springs. Reinstall the valve spring and spring retainer (Item 10). 12 10 11
Valve Clearance Inspection / Adjustment
IMPORTANT: Valve clearance inspection should be performed on a cold engine, at room temperature. NOTE: When a piston is at TDC of the compression stroke, both rocker arms will be loose and the cylinder TDC mark on the flywheel will be visible in the timing port (Item 1).
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6. Using a valve spring compressor tool, compress the valve spring. 7. Insert the valve keeper (Item 11) and slowly release the tension in the valve spring. Reinstall the valve cap (Item 12). 8. Repeat steps on all remaining valves.
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1 NOTE: The No. 1 piston is on the flywheel end of the engine. The firing order is 1-3-2. 1. Remove the intake manifold / valve cover. 2. Bring No. 1 piston to TDC of the compression stroke. 3. Insert a feeler gauge between rocker arm and valve cap and record the measured valve clearance.
Valve Clearance 0.006 - 0.010" (0.15 - 0.25 mm)
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= In. / mm.
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ENGINE
4. If adjustment is required, proceed to the next step. NOTE: No valve clearance when the piston is at TDC of the compression stroke indicates extreme wear or damage to the cylinder head or valves. 5. Loosen the valve adjusting screw lock nut (Item 2) and valve adjusting screw (Item 3) on the rocker arm. Check the valve for inclination of the valve cap, entrance of dirt or wear.
Cylinder Head Installation
NOTE: Use new gaskets, O-rings and seals for the reassembly of the cylinder head. NOTE: Generously oil all components during reassembly to prevent premature wear or damage. 1. Carefully clean both the combustion surface of the cylinder head and the top surface of the cylinder block. Install a new cylinder head gasket on the cylinder block. 2. Position the cylinder head on the cylinder head gasket. 3. Lightly oil the threads of the cylinder head bolts. Tighten the bolts to the specified sequence shown below. Tighten bolts to specification.
3
2
6. Insert a feeler gauge of the correct thickness between rocker arm and valve cap. Turn the valve adjustment screw to adjust the valve clearance so there is a slight "drag" on the feeler gauge when sliding it between the rocker arm and valve cap. Tighten the valve adjusting screw lock nut. Recheck the clearance. NOTE: Valve clearance will decrease slightly when the lock nut is tightened. Initial clearance adjustment should be made slightly on the "loose" side before tightening the lock nut.
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7. Apply oil to the contact surface between adjusting screw and push rod. 8. Rotate the crankshaft and measure the next cylinder. Continue until all valves are adjusted.
4. Insert the push rods in their respective positions.
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Cylinder Head Bolts: Step 1: Torque all bolts to 21 ft-lbs (28 Nm) Step 2: Torque all bolts to 42 ft-lbs (56 Nm)
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ENGINE
Intake Manifold / Valve Cover Assembly
1. Reinstall the glow plugs (Item 1) and tighten to specification. Reinstall the electrical harness (Item 2). 2 NOTE: Do not damage the threads in the end of the crankshaft when removing the crankshaft pulley. 1
CAMSHAFT AND TIMING GEARS
Timing Gearcase Cover Removal
1. Remove the crankshaft pulley bolt and washer.
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2. Remove the crankshaft pulley with a gear puller.
4. Remove the gear case cover (Item 1).
2. Lightly grease a new valve cover gasket. Place the gasket in the groove of the intake manifold / valve cover. 3. Place the valve cover on the cylinder head. Reinstall and tighten bolts securely. 4. Reinstall the exhaust manifold using a new gasket. Tighten the bolts and nuts securely. 5. Reinstall the fuel injectors.
6. Reinstall the high pressure and return fuel injection lines.
IN
8. Reinstall the alternator.
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7. Reinstall the coolant pump.
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5. Remove the dowel pins (Item 2).
Timing Gearcase Cover Installation
NOTE: The gear housing must be installed prior to reinstalling the camshaft. 1. If removed, reinstall the camshaft end plate (Item 3), key and camshaft gear (Item 4) onto the camshaft using a press. Heat the gear to 350 - 390°F(180 200°C) and press onto the end of the camshaft.
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3. Remove the bolts that retain the gear case cover to the cylinder block and oil pan.
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ENGINE
2. Lubricate the camshaft with clean engine oil or assembly lube. Slowly insert the camshaft through the front of the engine. 3. Reinstall and tighten the cap screws (Item 5). 4. Lubricate the camshaft lobes and tappets with clean oil or assembly lube. Reinstall the tappets in their respective locations in the cylinder block. Push the tappets fully into the tappet bores until they make solid contact with the camshaft. 5. If removed, reinstall the fuel injection pump. Adjust the fuel injection timing after installation. 6. Apply a continuous bead of ThreeBond Liquid Gasket to the mounting area of the gear case cover. 7. Reinstall the dowels. NOTE: Be sure to align the flats on the oil pump with the flats on the crankshaft gear. 8. Reinstall the timing gear case cover. Reinstall and tighten the gear case cover bolts. 9. Reinstall the crankshaft pulley. 10. Reinstall the washer and bolt. Tighten the bolt to specification.
Timing Gears Backlash - Checking
Prior to removing the timing gears, measure the gear backlash and determine the gear wear. Check the backlash between each pair of mating gears. If not within specification, replace both mating gears. Do not allow the gear being checked to move axially as excess end play could cause a false reading. 4 1
1 - Idler Gear 2 - Camshaft Drive Gear 3 - Crankshaft Drive Gear 4 - Injection Pump Drive Gear
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Crankshaft Pulley Bolt: 66 ft-lbs (90 Nm)
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Timing Gear Backlash for Crank, Cam, Idle and Fuel Injection Pump Gears Std: 0.0024 - 0.0047" (0.06 - 0.12 mm) Limit: 0.0055" (0.14 mm)
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3
= In. / mm.
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ENGINE
Idler Gear Inspection
Measuring Idler Gear-To-Crankshaft Gear Backlash 1. Install a dial indicator as shown.
Timing Gears Removal
1. Remove the bolts from the idler gear shaft (Item 1). Remove the idler gear shaft, idler gear (Item 2) and bushing (Item 3).
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2. Rotate the idler gear back and forth to check idler gear-to-crankshaft gear backlash. Total indicator reading is backlash. Record the measurement. Measuring Idler Gear-To-Camshaft Gear Backlash NOTE: Do not remove the crankshaft gear unless it is damaged and requires replacement. NOTE: Do not remove the camshaft gear unless it or the camshaft is damaged and requires replacement. 2. Do not remove the fuel injection pump drive gear unless absolutely necessary. Do not loosen or remove the four bolts (Item 4) retaining pump drive gear to the hub. Only remove the nut (Item 5) and washer (Item 6). Remove the pump drive gear and hub as an assembly using a gear puller. 1. Drive a small wooden wedge between the crankshaft gear and idler gear to prevent the idler gear from rotating. 2. Install a dial indicator to read camshaft gear backlash. Rotate camshaft drive gear against idler gear to measure backlash. Record the measurement. 3. Check the idler gear-to-fuel injection pump drive gear backlash in the same manner as the camshaft drive gear. Record the measurement.
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NOTE: Do not loosen or remove the four bolts retaining the fuel injection pump drive gear to the fuel injection pump hub. Correct fuel injection timing will be very difficult to achieve
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ENGINE
Timing Gears Installation
1. Set No. 3 piston to top dead center. 2. Lubricate the idler gear (Item 1), bushing (Item 2) and idler gear shaft (Item 3) with clean engine oil or assembly lube.
Camshaft Removal
1. Before removing the camshaft, check the camshaft end play using a dial indicator or a feeler gauge between the thrust plate and the front camshaft bearing.
2. Remove two bolts (Item 1) retaining the camshaft thrust plate (Item 2).
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3
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3. Rotate the camshaft until mark (B) is approximately at the 8 o'clock position and align the timing gears as shown. 7 4 5
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3 2 4 1 3. Extract the tappets (Item 3) through the top of the cylinder block. Mark the tappets so they can be reinstalled in the same location. 4. Slowly pull the camshaft assembly out of the engine being careful not to damage the front camshaft bushing. 5. Remove the camshaft gear (Item 4) only if the gear or camshaft require replacement. Use a knife-edge puller and a press to remove the gear. The gear is a shrink-fit and will need to be heated to 180 - 200°C (356 - 392°F) to remove.
4. Install the idler gear and idler gear shaft. Be sure the oil hole in the bushing is facing toward the top of the engine.
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5. Ensure all three timing marks (A, B, and C) are aligned.
6. When all gears are properly aligned, tighten the idler gear retaining bolts.
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4 - Idler Gear 5 - Camshaft Drive Gear 6 - Crankshaft Drive Gear 7 - Injection Pump Drive Gear
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Camshaft End Play Std: 0.0044 - 0.0098" (0.111 - 0.250 mm) Limit: 0.011" (0.28 mm)
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= In. / mm.
ENGINE
Camshaft Inspection / Servicing
Camshaft - Servicing 1. Use V-blocks and a dial indicator to check camshaft bend. Place the indicator on the center bearing journal. 4. Measure the diameter of the gear end (Item 2), intermediate (Item 3) and flywheel end (Item 4) bearing journals. 4
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2 2. Rotate the camshaft and observe the runout.
= In. / mm.
Camshaft Runout Std: 0.0000 - 0.0008" (0.00 - 0.02 mm) Limit: 0.0020" (0.05 mm)
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3. Measure the height of each lobe (Item 1).
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= In. / mm.
Cam Lobe Height Std: 1.3596 - 1.3648" (34.525 - 34.665 mm) Limit: 1.3499" (32.287 mm)
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Camshaft Gear End O.D. Std: 1.5724 - 1.5732" (39.940 - 39.960 mm) Limit: 1.5711" (39.906 mm)
Camshaft Intermediate O.D. Std: 1.5713 - 1.5722" (39.910 - 39.935 mm) Limit: 1.5699" (39.875 mm)
Camshaft Flywheel End O.D. Std: 1.5724 - 1.5732" (39.940 - 39.960 mm) Limit: 1.5711" (39.906 mm)
Inspection Of Camshaft Insert Bores 1. There are no camshaft bushing in this engine. Therefore, measure the camshaft bore ID in the cylinder block. If the bore ID is out of the specification, it is required to replace the cylinder block.
Camshaft Gear End I.D. Std: 1.5748 - 1.5758" (40.000 - 40.025 mm) Limit: 1.5787" (40.100 mm) Camshaft Intermediate I.D. Std: 1.5748 - 1.5758" (40.000 - 40.025 mm) Limit: 1.699" (39.875 mm) Camshaft Flywheel End I.D. Std: 1.5724 - 1.5732" (39.940 - 39.960 mm) Limit: 1.5787" (40.100 mm)
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= In. / mm. = In. / mm.
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ENGINE
Idler Gear And Shaft - Servicing 1. Measure the outside diameter (Item 1) of the idler gear shaft (Item 2). 4
CRANKSHAFT AND PISTONS
Piston and Connecting Rod Removal / Inspection
NOTE: Keep the piston pin parts, piston assemblies and connecting rod assemblies together to be returned to the same position during the reassembly process. Label the parts using an appropriate method.
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2
= In. / mm.
Idler Gear Shaft O.D. Std: 1.1795 - 1.1803" (29.959 - 29.980 mm) Limit: 1.1779" (29.919 mm) 2. Measure the inside diameter (Item 3) of the idler gear bushing (Item 4).
1. Using a feeler gauge, measure the connecting rod side clearance. 2. If the measurement is out of specification, replace the crankshaft, connecting rod or both.
= In. / mm.
Idler Gear Bushing I.D. Std: 1.1811 - 1.1821" (30.000 - 30.025 mm) Limit: 1.1837" (30.066 mm)
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NOTE: Mark the connecting rod caps and connecting rods so the caps and connecting rods stay together. 3. Remove the bearing cap. Do not remove the bearing inserts at this time.
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NOTE: Pistons can fall from the cylinder block if engine is inverted. Rotate the engine so the connecting rods are horizontal before removing the connecting rod caps.
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NOTE: Engines with high operating hours may have a ridge near the top of the cylinders that will catch the piston rings and make it impossible to remove the pistons. Use a suitable ridge reamer to remove ridges and carbon prior to removing the pistons.
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4. Wipe oil from the bearing insert and crankshaft journal surfaces. NOTE: Do not allow the connecting rod to contact the crankshaft journal during piston removal. Damage to the bearing journal may result. 9. Use a wooden dowel against the connecting rod and tap the piston / connecting rod assembly out of the cylinder.
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10. Mark the cylinder number on the piston and connecting rod.
3 4 5. Place a piece of PLASTIGAGE® (Item 1) along the full width of the bearing insert. NOTE: DO NOT rotate crankshaft when using PLASTIGAGE. A false reading may result. 6. Reinstall the bearing cap. Tighten the bolts to 17 - 20 ft-lbs (23 - 28 Nm). 5 8
7. Remove the bearing cap. Compare the width of the flattened PLASTIGAGE (Item 1) to the graduation marks on the package. This will be the oil clearance.
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= In. / mm.
Connecting Rod Bearing Oil Clearance Std: 0.0008 - 0.0023" (0.020 - 0.058 mm) Limit: 0.0043" (0.110 mm) 8. Repeat with the remaining connecting rods.
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12. Remove the compression rings (Item 3) from the piston using a piston ring expander. 13. Remove the oil ring (Item 4) from the piston using a piston ring expander. 14. Remove the snap rings (Item 5) from the wrist pin. 15. Remove the wrist pin (Item 6) and connecting rod (Item 7) from the piston (Item 8). 16. Repeat steps until all pistons are removed and dissembled.
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11. Remove the bearing inserts (Item 2).
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ENGINE
Piston Inspection
NOTE: On an engine with low hours, the pistons and piston rings may be reused if they are found to be within specifications. The pistons and piston rings must be reinstalled in the same cylinders from which they were originally removed. NOTE: On an engine with high hours, the piston rings should be replaced and the cylinder honed or replaced. The piston should be replaced as necessary. 1. Clean piston ring grooves using a piston ring groove cleaning tool. Follow manufacturer's instructions for correct operation. 2. Wash the pistons in an appropriate solvent using a soft brush. 3. Visually inspect each piston for cracks. Pay particular attention to the ring lands between the piston ring grooves. 4. Measure the diameter of the piston skirt at 90° to the wrist pin bore. Measurements must be taken at a specified distance (Item 1) from the bottom of the piston, based on engine model. 5. Subtract the piston measurement from the greatest measurement acquired during cylinder inspection to obtain piston-to-cylinder clearance.
= In. / mm.
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Piston Outer Diameter Std: 2.8331 - 2.8343" (71.960 - 71.980 mm) Limit: 2.8313" (71.915 mm)
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7. Measure the outside diameter of the wrist pin in three places and at 90°.
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= In. / mm.
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= In. / mm.
Piston Pin Bore Diameter Std: 0.8661 - 0.8665" (22.000 - 22.009 mm) Limit: 0.8677" (22.039 mm)
Wrist Pin O.D. Std: 0.8659 - 0.8661" (21.995 - 22.000 mm) Limit: 0.8648" (21.965 mm)
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= In. / mm.
6. Measure the diameter of the wrist pin bore on both sides of the piston. Record the measurements.
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Piston to Cylinder Clearance 0.0004 - 0.0028" (0.010 - 0.070 mm)
ENGINE
8. Using a micrometer, measure the thickness of each piston ring. 10. To measure piston ring end gap, insert each compression piston ring (Item 2), one at a time, into the cylinder. Use a piston with the piston rings removed to slide the ring into the cylinder bore until it is approximately 1.18 in. (30 mm) (Item 3) from the bottom of the bore. Remove the piston. Measure the end gap (Item 4) of each piston ring.
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Top and Second Ring Width Std: 0.0579 - 0.0587" (1.470 - 1.490 mm) Limit: 0.0571" (1.450 mm) Oil Ring Width Std: 0.1170 - 0.1177" (2.970 - 2.990 mm) Limit: 0.1161" (2.950 mm)
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= In. / mm.
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9. Place each compression piston ring in the groove as shown. Use a feeler gauge to measure the clearance between the piston ring and the piston ring land. Replace the piston if not within specification.
Top Ring End Clearance Std: 0.0039 - 0.0098" (0.100 - 0.250 mm) Limit: 0.0013" (0.034 mm) Second Ring End Clearance Std: 0.0098 - 0.0157" (0.250 - 0.400 mm) Limit: 0.0193" (0.490 mm) Oil Ring End Clearance Std: 0.0079 - 0.0177" (0.200 - 0.450 mm) Limit: 0.0217" (0.550 mm)
Top Ring Side Clearance Std: 0.0024 - 0.0039" (0.060 - 0.100 mm) Limit: Not Applicable
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= In. / mm.
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Second Ring Side Clearance Std: 0.0035 - 0.0049" (0.090 - 0.100 mm) Limit: 0.0096" (0.245 mm) Oil Ring Side Clearance Std: 0.0008 - 0.0022" (0.020 - 0.055 mm) Limit: 0.0071" (0.180 mm)
NOTE: Always check the piston ring end gap when installing new piston rings. Use a piston ring end gap filing tool to adjust the piston ring end gap on new piston rings. 11. Repeat the above steps for each cylinder and piston assembly.
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2 3 4
3
= In. / mm.
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ENGINE
Connecting Rod Inspection
1. Measure the inside diameter of the connecting rod small end. 3. Place the connecting rod bearing inserts into the connecting rod and connecting rod cap. Install the rod cap and tighten the bolts to 83 - 90 ft-lbs (113 - 123 Nm). 4. Measure the inside diameter.
= In. / mm.
Connecting Rod Small End I.D. Std: 0.8671 - 0.8678" (22.025 - 22.042 mm) Limit: 0.7902" (20.072 mm)
2. Measure the connecting rod twist (Item 1). If the twist is outside the limit, you must replace the connecting rod.
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Connecting Rod Twist per 100 mm (4.0") Std: Less than 0.001" (0.03 mm) Limit: 0.003" (0.08 mm)
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= In. / mm.
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Connecting Rod Journal Bearings I.D. 1.4954 - 1.4965" (37.982 - 38.010 mm)
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ENGINE
Cylinder Honing and Boring
If the cylinder walls are scuffed, scored, out-of-round, or tapered beyond specifications, rebore and hone to restore cylinders to usable condition. Slight imperfections can be corrected by honing alone. Boring Significant cylinder damage may be corrected by boring the cylinder to an oversize dimension. See the parts manual for available oversize pistons and piston rings. · A bored cylinder should always be finished with a hone to properly prepare the cylinder surface so the new piston rings will seat properly. · After the cylinder has been bored and honed, install the appropriate oversize pistons and piston rings. Honing Minor cylinder imperfections may be corrected by using a rigid cylinder hone. Be sure not to exceed the maximum cylinder bore specification. Deglazing
Piston and Connecting Rod Installation
NOTE: Proceed slowly. Do not force assemble unless a pressing operation is required. All parts must be clean and lubricated when assembled. NOTE: Use new gaskets, seals and O-rings during assembly. Generously apply clean engine oil to all internal parts during assembly. 1. If removed, install a new wrist pin bushing using a press and the appropriate service tool. Be sure to align the oil holes. 2. Reinstall one snap ring into the piston. Ensure the snap ring is securely seated in the groove. NOTE: When correctly assembled, the piston identification mark (Item 1) stamped on top of the piston will be on the opposite side of the connecting rod as the match marks (Item 2) stamped into the connecting rod and rod cap. When installed in the cylinder, the embossed mark (Item 3) cast into the rod will face the flywheel end of the engine.
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A used cylinder that did not require boring or honing, should always be deglazed with a ball hone before installing new piston rings. This will properly prepare the cylinder surface to allow new piston rings to seat properly.
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NOTE: Do not allow the honing tool to operate in one position for any length of time. Damage to the cylinder wall will occur. · Use a 50:50 mixture of diesel fuel and engine oil as a honing fluid. · Use a 300-grit hone at 300 - 1200 rpm. · When honing is completed, wash the cylinder block with hot water and soap. 2
NOTE: Solvents will not adequately remove honing residue, resulting in premature piston and ring wear. Always wash cylinders using hot, soapy water. The cylinder wall is adequately cleaned when a white rag wiped in cylinder comes out clean. Rinse with hot water and dry with compressed air. Apply clean engine oil to all steel surfaces to prevent rusting.
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NOTE: When honing a cylinder, with either a ridged hone or a ball hone, move the rotating hone up and down in the cylinder bore to accomplish a 30° - 40° crosshatch pattern. This will provide the ideal surface for the proper seating of new piston rings.
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NOTE: The actual appearance of match marks will vary but they will always be in the same locations.
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ENGINE
3. Place the connecting rod into the piston. The match marks on the connecting rod and cap must be on the opposite side as the piston identification mark on the top of the piston. 4. Lubricate and install the wrist pin through the piston and connecting rod. 6. Install the oil ring expander (Item 5). Install the oil ring (Item 6). NOTE: The oil ring expander end gap must be located 180° from the oil ring end gap.
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5
NOTE: If installing new piston rings the end gap must be checked and adjusted as necessary. Use a piston ring end gap filing tool to adjust the piston ring end gap on new piston rings. NOTE: Reinstall the top and second piston rings with the stamped "makers mark" (Item 4) facing the top of the piston. The "makers mark" may vary in appearance but will always be located on the top surface of the piston ring adjacent to the piston ring gap. The oil ring and oil ring expander can be installed either side up.
7. Install the second compression ring (Item 7). This ring is identified by its dark color and tapered face profile. 8. Install the top compression ring (Item 8). This ring is identified by its silver color and barrel-shaped face profile. 9. Stagger the piston ring end gaps at 120° apart. Do not position the top piston ring end gap in line with the wrist pin. NOTE: Do not allow the connecting rod to contact the crankshaft journal during piston installation. Damage to the crankshaft bearing journal may result. 10. Lubricate piston, piston rings and cylinder with clean engine oil or assembly lubricant.
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NOTE: Always use a piston ring expander when installing piston rings. Never attempt to install piston rings by hand.
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5. Install the second snap ring and ensure it is securely seated in the groove.
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11. Rotate the crankshaft so the crankpin for the piston being installed is near bottom dead center.
Cylinder Bore - Inspection
1. Ensure that oil passages are clear and unobstructed. 2. Check for discoloration or evidence of cracks. If a fracture is suspected, use the color check method or the MAGNAFLUX® method to determine if the cylinder block is fractured. 3. Measure cylinders for roundness, taper, and inspect for evidence of scoring. Consider honing, re-boring or replacing the cylinder block if the measurements are not within specific