Polaris Sportsman 800 Efi 2005 - Page 68

ENGINE
3.14
700/800 EFI ENGINE SERVICE DATA
Cylinder / Piston / Connecting Rod EFI Engine No.
EH680OLE
EFI Engine No.
EH780OLE
Piston
Ring
Piston ring installed
gap
Top ring
Std 0.0059-- 0.0138”
(0.15 ± 0.35 mm)
0.0059 -- 0.0138”
(0.15 ± 0.35 mm)
g
g
p
Limit
> 15% Leakdown > 15% Leakdown
Second
ring
Std 0.0098 -- 0.0197”
(0.25 ± 0.50 mm)
0.0098 -- 0.0197”
(0.25 ± 0.50 mm)
g
Limit
> 15% Leakdown > 15% Leakdown
Oil ring
Std 0.0196” ± .00984”
(0.50 ± 0.25 mm)
0.0196” ± .00984”
(0.50 ± 0.25 mm)
Limit
> 15% Leakdown > 15% Leakdown
Standard clearance
piston ring to ring
Top ring
Std 0.0024” ± 0.0008I
(0.060 ± 0.020 mm)
0.0024” ± 0.0008I
(0.060 ± 0.020 mm)
p
g
g
groove
Limit
> 15% Leakdown > 15% Leakdown
Second
ring
Std 0.0028” ± 0.0008I
(0.070 ± 0.020 mm)
0.0028” ± 0.0008I
(0.070 ± 0.020 mm)
g
Limit
> 15% Leakdown > 15% Leakdown
Connect-
ing Rod
Connecting rod small end ID .789 -- .78841”
(20.030 -- 20.015 mm)
.7096” ± 0.0003
(18.023± .008 mm)
g
Connecting rod small end ra-
dial clearance
Std 0.00098” ± 0.00039”
(0.025 ± 0.010 mm)
Same
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” ± 0.00591” (0.30
± 0.15 mm)
Same
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” ± 0.00006”
(0.0038 ± 0.0015 mm)
Same
Crankshaft Crankshaft runout limit 0.00236” (0.060 mm)
Same
KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side;
PTO: Power Take Off Side