1996 To Current Engine Specifications; Piston Identification - Polaris Magnum 2x4 Service Manual

1996 to Current Engine Specifications
Machine Model Engine Cyl.Disp. Bore Stroke
mml
Model
cc's
mm/in.
in.
Trail Blazer EC25PFE-09/11 244 72/2.8346 60/2.362
Trail Boss EC25PFE-08/10
Xpress 300
EC28PFE-01,
283
74.5/2.935
65/2.561
Xplorer 300 02
300
Xpress 400
EC38PLE-
379
83/3.270 70/2.758
Xplorer 4x4 04, 06
Sportsman 400
4006x6
Sport EC38PLE- 379 83/3.270 70/2.758
Scrambler 400 05,07,09
Magnum 2x4 EH42PLE- 425 87.9/3.461 70/2.758
Magnum 4x4
01,02
Magnum 6x6
Sportsman 500 EH50PLE- 498 92/3.622 75/2.953
Xplorer 500 01,05,06,07
Big Boss 500
6x6
Scrambler 500 EH50PLE-02, 498 92/3.622 75/2.953
04
Piston Identification
Ring End
Gap
in. (mm)
.009-.018
(.23-.46)
.012-.022
(.31-.56)
.007-.015
(.18-.38)
.007-.015
(.18-.38)
.008-.015
(.20-.38)
.008-.015
(.20-.38)
.008-.015
(.20-.38)
ENGINE
Engine Specifications
Piston Clearance Engine Op-
Clearance Svc. Limit erating
in. (mm) in. (mm) RPM
.0011-.0021 .006 5800
(.03-.05) (.15)
6000
.0012-.0026 .006
5600
(.03-.07) (.15)
.0023-.0037
.006 5700
(.06-.09) (.15)
.0023-.0037 .006 5700
(.06-.09)
(.15)
6000
.0006-.0018 .0024 6000
(.015-.046)
(.061)
.0006-.0018 .0024 6000
(.015-.046) (.061)
.0006-.0018 .0024 6000
(.015-.046) (.061)
Note the directional and identification marks when viewing the pistons from the top. The letter "F", "-+", "...-" or:
must always be toward the flywheel side of the engine. The other numbers are used for identification as to
diameter, length and design. Two stroke rings are keystone design. Four stroke engine rings are rectangular
profile. The numbers or letters on all rings (except 4-stroke oil control rings) must be positioned upward. See text
for 4 stroke oil control ring upper rail installation. Use the information below to identify pistons and rings.
Engine Model No. Oversize Available*
(mm)
EC25PFE-08, 09,10, 11
.25
.50
1.00
EC28PFE-01, 02 .25
.50
EC38PLE-04, 05 .25
.50
EC38PLE-06, 07 .25
.50
EH42PL-01 .25
.50
EH50PL-01, 02, 03 .25
.50
*
Pistons and rings marked 25 equal .25mm (.010") oversized
Pistons and rings marked 50 equal .50mm (.020") oversized
Piston Length
68mm
70mm
78mm
78mm
66mm
72mm
Pistons and rings marked 10 equal 1.0mm (.040") oversized (250 engines only)
Polaris Industries Inc.
3.3
Standard Piston
Identification
3W, 4W
28
38A
38B
B
C
5/98