Rebuilding Polaris 850 - Polaris ATV Forum
Polaris Highlifter Discuss the new Polaris Highlifter 850 and Highlifter 1000

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post #1 of 8 (permalink) Old 07-04-2019, 11:27 AM Thread Starter
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Rebuilding Polaris 850

Installed a crank kit when I start to assemble the lower crankcase I have a gap on the end opposite of the counter balance seal.

I've loaded what should be 8 pictures to the Gallery 5 here. The gap is on the end opposite the counter balance seals. The crank kit came with the bearings and are stamped std. However the end in question the insert does not go flush with the case. I tried to show in a photo.
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post #2 of 8 (permalink) Old 07-05-2019, 08:45 AM
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If the ends of the shell does net set flush with the surface of the case, that's the problem. If you place the shells around the journal, do the ends of the shells touch without clearance between the shells and the journal?

What year and model are you working on?
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post #3 of 8 (permalink) Old 07-05-2019, 09:37 AM Thread Starter
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It's a 2019. Yes the shells, inserts, touch around the crank without clearance with the crank installed in the upper case. The shell that does not sit flush is the one pictured. Thanks for responding.
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post #4 of 8 (permalink) Old 07-05-2019, 09:39 AM Thread Starter
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Polaris SPORTSMAN 850 HIGH LIFTER - A19SXN85A8
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post #5 of 8 (permalink) Old 07-05-2019, 11:02 AM
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Are the numbers on the shells the same? Are you working with the original cases? What happened to the engine to require a rebuild?
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post #6 of 8 (permalink) Old 07-05-2019, 12:08 PM
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I am at a loss as the the cause of the situation - I would have to have the parts in hand to reach a conclusion

That happens if you put the bearings in the case and set them together without the crankshaft in place?
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post #7 of 8 (permalink) Old 07-16-2019, 10:04 AM Thread Starter
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I finally got where I could look at the motor again. I removed the crankshaft and counter balance shafts. The cases go together without a gap with the bearing inserts installed in the two halves. I tried the old crankshaft just to see. The gap returned. I've checked bearing numbers they all correspond to polaris part numbers for standard bearings. I now feel the issue is in the center bearing area causing a high spot and gap. Any suggestions will be helpful.
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post #8 of 8 (permalink) Old 07-17-2019, 06:26 AM Thread Starter
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I took a few more measurements this morning of the lower case where I'm having issue. The depth of the radius was within .001 of what I call the fore crank bearing and aft where the insert protrudes above the case a total of .062". I measured the diameters and they were within .002. I checked the alignment of the 3 main bearing bores with a straight edge both sides of bore and the bottom. They were within .0015. I do no not see a problem. So, I installed the inserts in the lower case then laid the crank into position. The aft insert went almost flush with the case. Interesting. Any thoughts?
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