Polaris GENERAL 2016 Service Manual page 93

PISTON / RINGS / CONNECTING ROD / CRANKSHAFT / BALANCE SHAFT
ITEM
Standard O.D. - Measured 90° to pin, 0.39 in. (10
mm) up from piston skirt
Piston
Piston Pin Bore I.D. (Standard)
Piston Pin O.D.
Top Ring
Installed
Second Ring
Gap
Piston Ring
Oil Control Rails
Top Ring
Ring to
Groove
Second Ring
Clearance
Connecting Rod Small End I.D.
1 - Marking Conn. Rod Big End Bore I.D.
Connecting
Rod
2 - Marking Conn. Rod Big End Bore I.D.
3 - Marking Conn. Rod Big End Bore I.D.
B - Marking
Main Journal O.D.
G - Marking
Main Journal O.D.
Y - Marking
Main Journal O.D.
B - Marking
Rod Journal O.D.
Crankshaft
G - Marking
Rod Journal O.D.
Y - Marking
Rod Journal O.D.
Crankshaft Runout Limit (PTO and MAG)
Balance
Bearing Journal O.D. (Standard)
Shaft
Oil Pressure Minimum Specification (using Polaris engine oil at operating temperature)
*Additional oil may be required after complete engine disassembly. Check level after filling and add oil as
needed.
9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual
© Copyright Polaris Industries Inc.
3.6597 ± .0003" (92.959 ± 0.008 mm)
.7877 - .7881" (20.009 - 20.018 mm)
.7873 - .7875" (20.000 - 20.005 mm)
.010 - .014" (0.25 - 0.35 mm)
.015 - .025" (0.37 - 0.63 mm)
.008 - .028" (0.20 - 0.70 mm)
.0007 - .0023" (0.020 - 0.060 mm)
.7879 - .7885" (20.015 - 20.030 mm)
1.7318 - 1.7321" (43.989 - 43.996 mm)
1.7321 - 1.7323" (43.996 - 44.003 mm)
1.7323 - 1.7326" (44.003 - 44.010 mm)
1.6140 - 1.6143" (40.996 - 41.004 mm)
1.6137 - 1.6140" (40.988 - 40.995 mm)
1.6134 - 1.6137" (40.980 - 40.987 mm)
1.6118 - 1.6122" (40.942 - 40.950 mm)
1.6115 - 1.6118" (40.934 - 40.941 mm)
1.6112 - 1.6115" (40.926 - 40.933 mm)
1.4939 - 1.4946" (37.946 - 37.962 mm)
FLUID CAPACITY
Oil Capacity *: 2.5 Qt (2.4 L)
Oil Type: PS-4 5W-50 Full Synthetic
Ambient Temp Range: -35° F to 100° F
PS-4 10W-40 Extreme Duty Full Synthetic
Ambient Temp Range: 0° F to 120° F
10 PSI (69 kPa) @ 1200 RPM
40 PSI (276 kPa) @ 7000 RPM
ENGINE / COOLING SYSTEM
STANDARD
1.6129" (40.970 mm)
1.6129" (40.970 mm)
1.6129" (40.970 mm)
1.6104" (40.906 mm)
1.6104" (40.906 mm)
1.6104" (40.906 mm)
Less than .001" (0.025
-
1.4921" (37.900 mm)
SERVICE LIMIT
-
.7893" (20.05 mm)
.7866" (19.98 mm)
.0196" (0.5 mm)
3
.028" (0.70 mm)
.0354" (0.9 mm)
.0047" (0.12 mm)
.7897" (20.06 mm)
-
-
-
mm)
3.7