Polaris 2005 Sportsman MV7 Service Manual page 69

600 ENGINE SERVICE DATA
Cylinder / Piston / Connecting Rod
Cylinder Surface warpage limit (mating with cyl-
inder head)
Cylinder bore
Taper limit
Out of round limit
Piston clearance Piston clearance
Boring limit
Lifter Outer Diameter
Block Bore
Piston
Standard inner diameter of piston pin
bore
Piston Pin
Outer diameter
Standard clearance-piston pin to pin
bore
Degree of fit
Piston Piston Piston ring installed Top ring Piston ring installed
Ring g g gap
Standard clearance Top ring Standard clearance
-
piston ring to ring i t i t
groove groove
Connect- Connecting rod small end ID
i ing Rod R d
Connecting rod small end ra- g
dial clearance di l l
Connecting rod big end side Connecting rod big end side
clearance
Connecting rod big end radial Connecting rod big end radial
clearance
Crankshaft Crankshaft runout limit
KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side;
PTO: Power Take Off Side
Std
Limit
Std
Std
Std
Top ring
Limit
Second Second
ring
Limit
Oil ring Oil ring
Limit
Top ring
Limit
i
Second Second
ring
Limit
Std
Limit
Limit
Engine No. - - EH590ALOE
0.004" (0.10 mm)
3.0118" (76.5mm)
0.00031" (0.008 mm)
0.00030" (0.0075 mm)
.0022" ± .00067" (.055 ± .017 mm)
N/A
0.84245" ± 0.00025" (21.39 8± 0.00635 mm)
0.8438" ± 0.00062"(21.4322 ± 0.0157 mm)
3.0096" ± .00035I (76.445 ± .009 mm)
0.78757" ± .00098I (20.0045 ± 0.0025 mm)
0.7874" -- .7872" (20 -- 19.995 mm)
0.00027" ± 0.00019" (0.007 ± 0.005 mm)
Piston pin must be a push (by hand) fit at 68°
F (20° C)
0.01181" ± 0.00393" (0.30 ± 0.10 mm)
0.01476" ± 0.00492" (0.375 ± 0.125 mm)
0.00984" ± .00393" (0.25 ± 0.10 mm)
0.0019" ± 0.00069" (0.0475 ± 0.0175 mm)
0.0017" ± 0.00049I (0.0425 ± 0.0125 mm)
.789" -- .78841". (20.030 -- 20.015 mm)
0.00098" ± 0.00039" (0.025 ± 0.010 mm)
0.01181" ± 0.00591" (0.30 ± 0.15 mm)
0.00015" ± 0.00006" (0.0038 ± 0.0015 mm)
0.00236" (0.060 mm)
ENGINE
3.11