Polaris 2009 Sportsman XP 850 Service Manual page 98

ENGINE
Cylinder - Surface warp limit
(mating with cylinder head)
Cylinder Bore - Standard
Cylinder
Cylinder Out of Round Limit
Cylinder to Piston Clearance
Piston - Standard O.D. - Measured 90 degrees to
pin, 1.3 in. (33.0 mm) down from piston crown.
Piston
Piston Pin Bore I.D. (Standard)
Piston Pin Outside Diameter
Piston Pin - Standard Clearance - Piston Pin to
Piston Pin
Pin Bore
Piston Pin - Degree of Fit
Installed
Piston Ring
Ring to
Groove
Clearance
Connecting Rod Small End I.D.
Connecting Rod Small End
Diametral Clearance
Connecting Rod
Connecting Rod Big End
Side Clearance
Connecting Rod Big End
Diametral Clearance
Crankshaft Runout Limit (See procedure)
Crankshaft
Main Journal Diameter (Standard)
Connecting Rod Journal Diameter (Standard)
5.6
CYLINDER / PISTON (IN. / MM)
PISTON / RINGS / CONNECTING ROD / CRANKSHAFT (IN. / MM)
Top Ring - Standard
Top Ring - Service Limit
Second Ring - Standard
Gap
Second Ring - Service Limit
Oil Ring Rails - Standard
Oil Ring Rails - Service Limit
Top Ring - Standard
Second Ring - Standard
0.004" (0.10 mm)
3.4252" ± .0005 (87 mm ± .01mm)
0.0003" (0.0075 mm)
.0021" ± .0013" (.053 ± .03mm)
3.4231" ± .0008" (86.947 ± .02 mm)
0.7877" ± .0002" (20.007 ± .004 mm)
0.7873" ± .0001" (19.9975 ± .0025 mm)
0.0004" ± .0002" (0.0095 ± 0.0065 mm)
Piston pin must be a push fit (by hand) at 68° F (20° C)
0.008" - 0.014" (0.20 - 0.36 mm)
0.016" (0.41 mm)
0.014" - 0.024" (0.36 - 0.61 mm)
0.032" (0.81 mm)
0.020" ± 0.010" (0.51 ± 0.25 mm)
0.032" (0.81 mm)
0.0024" ± 0.0008" (0.060 ± 0.020 mm)
0.0028" ± 0.0008" (0.070 ± 0.020 mm)
0.7886" + 0.000 / - .015" (20.030 + 0.000 / - .015 mm)
0.00098" ± .0004" (0.025 ± 0.010 mm)
0.012" ± 0.0039" (0.30 ± .10 mm)
0.0098" - .0023" (0.025 - .059 mm)
PTO End Less than .001" (0.025 mm)
MAG End Less than .001" (0.025 mm)
2.1642" - 2.1649" (54.97 - 54.99 mm)
1.7718" - 1.7726" (45.005 - 45.025 mm)