Polaris Sportsman 850 - Page 80

3.8
CYLINDER / PISTON (IN. / MM)
Piston Pin
Piston Pin Outside Diameter 0.7873" ± .0001" (19.9975 ± .0025 mm)
Piston Pin - Standard Clearance - Piston Pin
to Pin Bore
0.0004" ± .0002" (0.0095 ± 0.0065 mm)
Piston Pin - Degree of Fit Piston pin must be push fit (by hand) at 68° F (20°
C)
PISTON / RINGS / CONNECTING ROD / CRANKSHAFT (IN. / MM)
Piston Ring
Installed
Gap
Top Ring - Standard 0.008” - 0.014” (0.20 - 0.36 mm)
Top Ring - Service Limit 0.016” (0.41 mm)
Second Ring - Standard 0.014” - 0.024” (0.36 - 0.61 mm)
Second Ring - Service Limit 0.032” (0.81 mm)
Oil Ring Rails - Standard 0.020” ± 0.010” (0.51 ± 0.25 mm)
Oil Ring Rails - Service Limit 0.032” (0.81 mm)
Ring to
Groove
Clearance
Top Ring - Standard 0.0024” ± 0.0008” (0.060 ± 0.020 mm)
Second Ring - Standard 0.0028” ± 0.0008” (0.070 ± 0.020 mm)
Connecting Rod
Connecting Rod Small End I.D.
0.7886” + 0.000 / - .015” (20.030 + .000 / - .015
mm)
Connecting Rod Small End
Diametral Clearance
0.00098” ± .0004” (0.025 ± 0.010 mm)
Connecting Rod Big End
Side Clearance
0.012” ± 0.0039” (0.30 ± .10 mm)
Connecting Rod Big End
Diametral Clearance
0.0098” - .0023” (0.025 - .059 mm)
Crankshaft
Crankshaft Runout Limit Refer to Procedure
PTO End
Less than .001” (0.025 mm)
MAG End
Less than .001” (0.025 mm)
Main Journal Diameter (Standard) 2.1642” - 2.1649” (54.97 - 54.99 mm)
Connecting Rod Journal Diameter
(Standard)
1.7718” - 1.7726” (45.005 - 45.025 mm)
ENGINE / COOLING SYSTEM