Engine / Cooling
3.52
Engi ne Inspec tion -- All Engines
1. Position each piston ring 1/2I (1.3 cm) from the top
of the cylinder using the piston to push it squarely
into place. Measure installed gap with a feeler
gauge at both the top and bottom of the cylinder.
NOTE: A difference in end gap indicates cylinder taper.
The cylinder should be measured for excessive taper
and out of round. Replace rings if the installed end gap
exceeds the service limit.
NOTE: Always check piston ring installed gap after re-
boring a cylinder or when installing new rings.
Crankshaft Main Bearing Inspection
1. Clean crankshaft thoroughly and oil main and connecting rod bearings with Polaris Premium 2 cycle engine oil.
Carefully check each main bearing on the shaft.
NOTE: Due to extremely close tolerances, the bearings must be inspected visually, and by feel. Look for signs
of discoloration, scoring or galling. T urn the outer race of each bearing. The bearings should turn smoothly and
quietly. The inner race of each bearing should fit tightly on the crankshaft. The outer race should be firm with mini-
mal side to side movement and no detectable up and down movement. Replace any loose or rough bearings.
Connecting Rod (Big End) Side Clearance
1. Measure connecting rod big end side clearance with
a feeler gauge. Compare to specifications.
Piston Ring Installed Gap
STD: .014²-.019² (.36 - .48mm)
Service Limit: .028² (.71mm)
Connecting Rod Big End Side Clearance
Standard: .014 - .020² (.36-.51mm)
Service Limit: .022² (.56mm)
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