Polaris 1999 Sportsman 400 Service Manual page 142

136
Tab l e 4 ENGINE T OP END SPECIFICATIONS (continued)
CHAPTEI{
roun
Item New Service limit
mm (in.)
mm (in.)
Valve stem outer diameter
Intake
5.9950-5.965
(0.2360-0.2348)
Exhaust
5.945 -5.960
(0.2341-0.2346)
Valve guide (intake and exhaust)
Inside diameter
6.0-6 .012
(0.23 62-0 .2367)
Protrusion above head
17.5-18.0
(0.689 ·0.709)
Valve ste m-la-gu ide clearance
Intake
0.035-0.062 0.15
(0.0014-0.0024) (0.0059)
Exhaust
0.040-0.067 0.15
(0.0016-0.0026) (0.0059)
Valve ove rall length
Intake 101 .0
(3.976)
Exhaust
101 .2
(3.984)
Valve spr ings free length
Orange paint mark
44.05 42.05
(1.7342) (1.656)
Yellow paint mark 42 .0 40.0
(1.654) (1.575)
Cylinder block
Bore
91 .988-92.009
(3.6216-3 .6224)
Bore limit
0.5 (0.02 0)
Taper
0.050 (0.0 02 0)
Out of round
0 .05 0 (0.0020)
Top surface warp
0.050 (0.0020)
Piston
Outer d iame ter
Standard
91.96-91 .97
(3 .6206-3.6210)
0.25 mm overs ize
92 .21 -92.23
(3.6304 -3.6310)
0.50 mm oversize
92.46-92.47
(3.6403-3.6407)
Piston pin bore inside diameter
23.0-23.006
(0.99055-0.9057)
Piston
pin-to-piston
clearance
0.004-0.008
(0.0002-0.0003)
Piston-la-cylinder clearance
0.015-0.045 0 .060
(0.0006-0.00181) (0.0024)
Piston rings
End gap-Insta lled
Top and second
0.20-0.36 1.0
(0.0079-0.0138) (0.039)
Oil ring
0.20-0.70 1.5
(0.0079-0.0276) (0.059)
Side clearance
Top ring
0.040-0.080 0. 15
(0.0016-0.0031) (0.0059)
Second ri ng
0.030-0.070
0.15
(0.0012-0.0028) (0.0059)