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Polaris TRAIL BOSS 2003 User Manual

Polaris TRAIL BOSS 2003
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ENGINE
3.3
ES32PFE10 ENGINE SER
VICE
DAT
A
Cylinder / Piston / Connecting Rod ES32PFE10
Cylinder
Surface warpage limit (mating with cylinder
head)
.0020² (0.050 mm)
Cylinder bore Std 3.0906-3.0913² (78.50-78.520 mm)
Taper limit .0020² (0.050 mm)
Out of round limit .0020² (0.050 mm)
Piston clearance
Std .0015-.0032² (0.038-0.082 mm)
Limit .004² (0.11 mm)
Boring limit .0020² (0.5 mm)
Piston Outer diameter
Std 3.0881-3.0891² (78.438-78.462 mm)
.0098² (.25 mm)
OS
3.0980-3.0989² (78.688-78.712 mm)
.0197² (.50 mm)
OS
3.1078-3.1087² (78.938-78.962 mm)
Standard inner diameter of piston pin bore .7095-.7097² (18.007-18.013 mm)
Piston Pin
Outer diameter .7092--.7095² (18.001-18.007 mm)
Standard clearance-piston pin to pin bore 0.0-.0005² (0.0-0.012 mm)
Degree of fit Piston pin must be a push (by hand) fit at 68°
F(20° C)
Piston Ring Piston ring installed gap To p r ing
Std .0079-.0118² (0.20-0.30 mm)
g
g
g
p
p
g
Limit .039² (1.0 mm)
Second
i
Std .0138-.0197² (0.35-0.50 mm)
ring
Limit .039² (1.0 mm)
Oil ring
Std .0079-.0236² (0.20-0.60 mm)
g
Limit .059² (1.5 mm)
Piston Ring Standard clearance -
i
i
i
Top rin g
Std .0014-.0030² (0.035-0.075 mm)
g
piston ring to ring groove
p
g
Limit .0059² (0.15 mm)
Second
i
Std .0010-.0026² (0.025-0.065 mm)
ring
Limit .0059² (0.15 mm)
Connecting Rod
Connecting rod small end ID .7095-.7101² (18.007-18.023 mm)
g
Connecting rod small end radial
l
Std 0.0-.0009² (0.0-0.022 mm)
g
clearance
Limit .0012² (0.03 mm)
Connecting rod big end side clear-
Std .0028-.0118² (0.07-0.30 mm)
g
g
ance
Limit .0138² (0.35 mm)
Connecting rod big end bearing
l
Std 0.0007-0.0021² (0.019-0.053 mm)
g
g
g
clearance
Limit 0.0026² (0.065 mm)
Crankshaft
Crankshaft runout limit (PTO end) 0.0024² (0.060 mm)
Crankshaft end play 0.002-0.008² (0.05-0.20 mm)
KEY - Std: Standard; OS: Oversize; ID: Inner Diameter;
OD: Outer Diameter; Mag: Magneto Side; PTO: Power
Take Off Side

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Polaris TRAIL BOSS 2003 Specifications

General IconGeneral
BrandPolaris
ModelTRAIL BOSS 2003
CategoryOffroad Vehicle
LanguageEnglish

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