Piston-To-Cylinder Clearance; Connecting Rod Inspection - Polaris GENERAL 2016 Service Manual

ENGINE / COOLING SYSTEM

PISTON-TO-CYLINDER CLEARANCE

Measure piston outside diameter at a point 10 mm
from the bottom of the piston, at a right angle to piston
pin bore.
Subtract measurement from maximum measurement
obtained in Step 4
3.54"Cylinder Inspection" procedure.
MEASUREMENT
Piston O.D. (Standard):
3.6597 ± .0003" (92.959 ± 0.008 mm)
Piston to Cylinder Clearance:
.0009 - .0019" (0.025 - 0.050 mm)

CONNECTING ROD INSPECTION

1. The 3 digit numbers stamped onto the intake side of
the connecting rod are serial numbers used to match
w
the rod cap with the rod stem
3.58
of Cylinder Inspectionpage
e
.
2. The number
exhaust side of the connecting rod represent the
q
up
bore diameter and weight grading of the connecting
rod.
3. Inspect the small end and big end of connecting rod
(and matching rod cap) for damage, galling of
surface or pitting.
4. Measure small end I. D. in two directions as shown.
Record
specifications. Replace connecting rod if worn past
the service limit specification.
Connecting Rod Small End I.D.:
.7879 - .7885" (20.015 - 20.030 mm)
5. Install matching rod cap on connecting rod (without
bearings) and install the bolts.
6. Tighten bolts snug, then torque to 13 ft-lbs (18 Nm).
9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual
r t
and letter stamped onto the
measurements and
MEASUREMENT
Service Limit:
.7897" (20.06 mm)
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