Polaris GENERAL 2016 User Manual

3
9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual
© Copyright Polaris Industries Inc.
3.7
PISTON / RINGS / CONNECTING ROD / CRANKSHAFT / BALANCE SHAFT
ITEM
STANDARD SERVICE LIMIT
Piston
Standard O.D. - Measured 90° to pin, 0.39 in. (10
mm) up from piston skirt
3.6597 ± .0003" (92.959 ± 0.008 mm)
-
Piston Pin Bore I.D. (Standard) .7877 - .7881" (20.009 - 20.018 mm) .7893" (20.05 mm)
Piston Pin O.D.
.7873 - .7875" (20.000 - 20.005 mm) .7866" (19.98 mm)
Piston Ring
Installed
Gap
Top Ring .010 - .014" (0.25 - 0.35 mm) .0196" (0.5 mm)
Second Ring .015 - .025" (0.37 - 0.63 mm) .028" (0.70 mm)
Oil Control Rails
.008 - .028" (0.20 - 0.70 mm) .0354" (0.9 mm)
Ring to
Groove
Clearance
Top Ring
.0007 - .0023" (0.020 - 0.060 mm) .0047" (0.12 mm)
Second Ring
Connecting
Rod
Connecting Rod Small End I.D. .7879 - .7885" (20.015 - 20.030 mm) .7897" (20.06 mm)
1 - Marking Conn. Rod Big End Bore I.D. 1.7318 - 1.7321" (43.989 - 43.996 mm)
-
2 - Marking Conn. Rod Big End Bore I.D. 1.7321 - 1.7323" (43.996 - 44.003 mm)
-
3 - Marking Conn. Rod Big End Bore I.D. 1.7323 - 1.7326" (44.003 - 44.010 mm)
-
Crankshaft
B - Marking
Main Journal O.D.
1.6140 - 1.6143" (40.996 - 41.004 mm) 1.6129" (40.970 mm)
G - Marking
Main Journal O.D.
1.6137 - 1.6140" (40.988 - 40.995 mm) 1.6129" (40.970 mm)
Y - Marking
Main Journal O.D.
1.6134 - 1.6137" (40.980 - 40.987 mm) 1.6129" (40.970 mm)
B - Marking
Rod Journal O.D.
1.6118 - 1.6122" (40.942 - 40.950 mm) 1.6104" (40.906 mm)
G - Marking
Rod Journal O.D.
1.6115 - 1.6118" (40.934 - 40.941 mm) 1.6104" (40.906 mm)
Y - Marking
Rod Journal O.D.
1.6112 - 1.6115" (40.926 - 40.933 mm) 1.6104" (40.906 mm)
Crankshaft Runout Limit (PTO and MAG)
-
Less than .001″ (0.025
mm)
Balance
Shaft
Bearing Journal O.D. (Standard) 1.4939 - 1.4946" (37.946 - 37.962 mm) 1.4921" (37.900 mm)
FLUID CAPACITY
Oil Capacity *: 2.5 Qt (2.4 L)
Oil Type: PS-4 5W-50 Full Synthetic
Ambient Temp Range: -35° F to 100° F
PS-4 10W-40 Extreme Duty Full Synthetic
Ambient Temp Range: 0° F to 120° F
Oil Pressure Minimum Specification (using Polaris engine oil at operating temperature)
10 PSI (69 kPa) @ 1200 RPM
40 PSI (276 kPa) @ 7000 RPM
*Additional oil may be required after complete engine disassembly. Check level after filling and add oil as
needed.
ENGINE / COOLING SYSTEM

Polaris GENERAL 2016 Specifications

General

Brand	Polaris
Model	GENERAL 2016
Category	Offroad Vehicle
Language	English