Polaris 2005 Sportsman MV7 Service Manual page 90

ENGINE
5 mm
Piston
Piston to Cylinder Clearance
600: .0022" ± .00067" (.055 ± .017 mm)
700: .0016" ± .00063" (.041 ± .016 mm)
Piston O.D.
600: 3.0096" ± .00035I (76.445 ± .009 mm)
700: 3.1477" ± .00012I (79.954 ± .003 mm)
PISTON/ROD INSPECTION
1. Measure piston pin bore.
Piston Pin Bore:
600: 0.00027" ± 0.00019"
(0.007 ± 0.005 mm)
700: 0.00059" ± 0.0002"
(0.015 ± 0.005 mm)
3.32
Piston Pin
2. Measure piston pin O.D. Replace piston and/or
piston pin if out of tolerance.
Piston Pin Measurement Locations
Piston Pin O.D.
0.7874" - - .7872" (20 - - 19.995 mm)
3. Measure connecting rod small end ID.
Connecting Rod Small End I.D.
.789" - - .78841". (20.030 - - 20.015 mm)
4. Measure piston ring to groove clearance by
placing the ring in the ring land and measuring
with a thickness gauge. Replace piston and rings
if ring-to-groove clearance exceeds service
limits.