Polaris Outlaw 500 Service Manual page 52

ES50PL Engine Service Data
Cylinder / Piston / Connecting Rod / Crankshaft
Surface warpage limit (mating with cylinder head)
Cylinder bore
Taper limit
Cylinder
Out of round limit
Piston clearance
Outer diameter
Piston
Piston Pin Bore Standard I.D.
Outer diameter
Piston pin to pin bore clearance
Piston Pin
Degree of fit
Piston Ring to ring groove clearance
Piston Ring installed gap
Connecting rod small end ID
Connecting rod small end radial
clearance
Connecting Rod
Connecting rod big end side clearance
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.
ES50PL
.002" (.05 mm)
Std 3.9055–3.9062" (99.20–99.22 mm)
.002" (.05 mm)
.002" (.05 mm)
Std .0018- .0025" (.046- .065 mm)
Limit .0039" (.10 mm)
Std 3.9037- 3.904" (99.155- 99.170 mm)
.9055- .9057" (23.001- 23.007 mm)
Std .9053- .9055" (23.001 - 23.007 mm)
.0002- .0004" (.001- .0011 mm)
Piston Pin must be a push (by hand)
fit at 68
Std .0012–.0028" (.030–.070 mm)
Top
Ring
Limit .0059" (.15 mm)
Std .0012–.0028" (.030–.070 mm)
Second
Ring
Limit .0059" (.15 mm)
Std .008–.012" (.20–.30 mm)
Top
Ring
Limit .027" (.7 mm)
Std .014–.019" (.35–.50 mm)
Second
Ring
Limit .031" (.8 mm)
Std .004–.019" (.10–.50 mm)
Oil Ring
Limit .039" (1.0 mm)
.9058- .9063" (23.007- 23.020 mm)
Std .0003- .0009" (.007- .024 mm)
Limit .0020" (.05 mm)
Std .0035- .0196" (.09- .50 mm)
Limit .0255" (.65 mm)
Std .0004- .0015" (.011- .038 mm)
Limit Same as standard
.0024" (.06 mm)
ENGINE
o o
F(20 C)
3
3.5