Polaris SPORTSMAN 700 2002 - Page 63

ENGINE
ENGINE
3.11
600 ENGINE SERVICE DATA
Cylinder / Piston / Connecting Rod Engine No. -- EH590ALOE
Cylinder
Surface warpage limit (mating with cyl-
inder head)
0.004” (0.10 mm)
Cylinder bore Std 3.0118” (76.5mm)
Taper limit 0.00031” (0.008 mm)
Out of round limit 0.00030” (0.0075 mm)
Piston clearance
P
i
s
t
o
n
c
l
e
a
r
a
n
c
e
Limit .0022” r .00067” (.055 r .017 mm)
Boring limit N/A
Lifter
Outer Diameter Std 0.84245” r 0.00025” (21.39 8r 0.00635 mm)
Block Bore Std 0.8438” r 0.00062”(21.4322 r 0.0157 mm)
Piston
Std 3.0096” r .00035I (76.445 r .009 mm)
Standard inner diameter of piston pin
bore
0.78757” r .00098I (20.0045 r 0.0025 mm)
Piston Pin
Outer diameter 0.7874” -- .0002” (20 -- .005 mm)
Standard clearance-piston pin to pin
bore
0.00027” r 0.00019” (0.007 r 0.005 mm)
Degree of fit Piston pin must be a push (by hand) fit at 68q
F(20q C)
Piston Piston rin
g
installed To
p
rin
g
P
i
s
t
o
n
Ring
P
i
s
t
o
n
r
i
n
g
i
n
s
t
a
l
l
e
d
gap
T
o
p
r
i
n
g
Limit 0.01181” r 0.00039” (0.30 r 0.01 mm)
g
g
Second
S
e
c
o
n
d
ring
Limit 0.01476” r 0.00492” (0.375 r 0.125 mm)
Oil rin
g
O
i
l
r
i
n
g
Limit 0.00984” r .00393” (0.25 r 0.10 mm)
Standard clearance To
p
rin
g
S
t
a
n
d
a
r
d
c
l
e
a
r
a
n
c
e
-
i
t
i
t
i
T
o
p
r
i
n
g
Limit 0.0019” r 0.00069” (0.0475 r 0.0175 mm)
piston ring to ring
g
r
o
o
v
e
Second
groove
S
e
c
o
n
d
ring
Limit 0.0017” r 0.00049I (0.0425 r 0.0125 mm)
Connect-
i
R
d
Connecting rod small end ID 0.789” r 0.00059”. (20.030 r 0.015 mm)
ing Rod
Connecting rod small end ra-
d
i
l
l
Std 0.00098” r 0.00039” (0.025 r 0.010 mm)
g
dial clearance
Connectin
g
rod bi
g
end side
C
o
n
n
e
c
t
i
n
g
r
o
d
b
i
g
e
n
d
s
i
d
e
clearance
Limit 0.01181” r 0.00591” (0.30 r 0.15 mm)
Connectin
g
rod bi
g
end radial
C
o
n
n
e
c
t
i
n
g
r
o
d
b
i
g
e
n
d
r
a
d
i
a
l
clearance
Limit 0.00015” r 0.00006” (0.0038 r 0.0015 mm)
Crankshaft Crankshaft runout limit 0.00236” (0.060 mm)
KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side;
PTO: Power Take Off Side
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