Piston-To-Cylinder Clearance - Polaris Sportsman 800 EFI 4x4 2012 Service Manual

ENGINE
4. Inspect cylinder for taper and out of round with a
telescoping gauge or a dial bore gauge. Measure in
two different directions, front to back and side to
side, on three different levels (1/2, down from top, in
the middle, and 1/2, up from bottom). Record
measurements. If cylinder is tapered or out of round
beyond .002", the cylinder must be replaced.
Cylinder Taper Limit:
.002" (9.05mm) Max.
Cylinder Out of Round:
Limit: .002" (.0 mm) Max.
800 Standard Bore Size
(Both Cylinders): 3.1496" (80 mm)
3.38

Piston-To-Cylinder Clearance

Measure piston outside diameter at a point 5 mm up from
the bottom of the piston at a right angle to the direction of
the piston pin.
Subtract this measurement from the maximum cylinder
measurement obtained in Step 5.
9924864 - 2012-2014 SPORTSMAN 800 / 6X6
© Copyright 2013 Polaris Sales Inc.