Polaris SPORTSMAN 600 2003 Service Manual page 84

5 mm
Piston
Piston to Cylinder Clearance
600: .0022" .00067" (.055
700: .0018" .00063" (.041
Piston O.D.
600: 3.0096" .00035I (76.445
700: 3.1477" .00012I (79.954
PISTON/ROD INSPECTION
1. Measure piston pin bore.
Piston Pin Bore:
600: 0.00027"
(0.007 0.005 mm)
700: 0.00059"
(0.015 0.005 mm)
3.32
Piston Pin
.017 mm)
.016 mm)
.009 mm)
.003 mm)
0.00019"
0.0002"
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.
ENGINE ENGINE