3.34
ENGINE
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Piston-to-Cylinder Clearance
1. Measure piston outside diameter at a point 40 mm
down from the top of the piston at a right angle to the
direction of the piston pin.
2. Subtract this measurement from the maximum
cylinder measurement obtained in Step 5 above.
Piston / Rod Inspection
1. Measure piston pin bore.
2. Measure piston pin O.D. Replace piston and/or piston
pin if out of tolerance.
3. Measure connecting rod small end ID.
Piston to Cylinder Clearance
E H 5 00 P L E ( 4 9 8c c )
Std: .0006-.0018” (.015-.045 mm)
E H 4 6 P L E (4 5 5 cc )
Std: .0006-.0028” (.015-.050 mm)
Piston O.D.:
E H 5 00 P L E ( 4 9 8c c )
Std: 3.6204-3.6215” (91.970-91.985 mm)
E H 4 6 P L E (4 5 5 cc )
Std: 3.4594-3.4600” (87.870-87.885 mm)
Piston Pin Bore:
.9055 - .9057” (23.0 - 23.006 mm)
Piston Pin O.D.
.9053 - .9055” (22.994 - 23.0 mm)
Piston Pin Measurement Locations
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