Polaris Sportsman 850 - Winch Operation

3.10
CYLINDER / PISTON (IN. / MM)
Cylinder Cylinder - Surface warp limit (mating with
cylinder head)
0.004" (0.10 mm)
Cylinder Bore - Standard 3.5630" ± .0005 (90.5 mm ± .012 mm)
Cylinder Out of Round Limit 0.0003" (0.0075 mm)
Cylinder to Piston Clearance .0020" ± .0012" (.05 ± .031 mm)
Piston
Piston - Standard O.D. - Measured 90° to
pin, 1.3 in. (33.0 mm) down from piston
crown.
3.5610" ± .0007" (90.450 ± .019 mm)
Piston Pin Bore I.D. (Standard) 0.7877" ± .0001" (20.007 ± .0025 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 ± 0.0055 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 0.012” - 0.022” (0.30 - 0.55 mm)
Top Ring - Service Limit 0.024” (0.60 mm)
Second Ring - Standard 0.039” - 0.047” (1.00 - 1.20 mm)
Second Ring - Service Limit 0.049” (1.25 mm)
Oil Ring Rails - Standard 0.008” - 0.028” (0.20 - 0.70 mm)
Oil Ring Rails - Service Limit 0.029” (0.75 mm)
Ring to
Groove
Clearance
Top Ring - Standard 0.0006” - 0.0024” (0.015 - 0.060 mm)
Second Ring - Standard 0.0006” - 0.0024” (0.015 - 0.060 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