Polaris Sportsman XP 1000 S 2020 Service Manual page 138

ENGINE / COOLING SYSTEM
CYLINDER / PISTON (IN. / MM)
Cylinder Cylinder - Surface warp limit (mating with
cylinder head)
Cylinder Bore - Standard
Cylinder Out of Round Limit
Cylinder to Piston Clearance
Piston Piston - Standard O.D. - Measured 90° to
pin, 1.3 in. (33.0 mm) down from piston
crown.
Piston Pin Bore I.D. (Standard)
Piston Pin Piston Pin Outside Diameter
Piston Pin - Standard Clearance - Piston Pin
to Pin Bore
Piston Pin - Degree of Fit
PISTON / RINGS / CONNECTING ROD / CRANKSHAFT (IN. / MM)
Installed
Gap
Piston Ring
Ring to
Groove
Clearance
Connecting Rod Small End I.D.
Connecting Rod Small End
Diametral Clearance
Connecting Rod
Connecting Rod Big End
Side Clearance
Connecting Rod Big End
Diametral Clearance
Crankshaft Runout Limit
PTO End
MAG End
Crankshaft
Main Journal Diameter (Standard)
Connecting Rod Journal Diameter
(Standard)
3.8
Top Ring - Standard
Top Ring - Service Limit
Second Ring - Standard
Second Ring - Service Limit
Oil Ring Rails - Standard
Oil Ring Rails - Service Limit
Top Ring - Standard
Second Ring - Standard
0.004" (0.10 mm)
3.5630" ± .0005 (90.5 mm ± .012 mm)
0.0003" (0.0075 mm)
.0020" ± .0012" (.05 ± .031 mm)
3.5610" ± .0007" (90.450 ± .019 mm)
0.7877" ± .0001" (20.007 ± .0025 mm)
0.7873" ± .0001" (19.9975 ± .0025 mm)
0.0004" ± .0002" (0.0095 ± 0.0055 mm)
Piston pin must be push fit (by hand)
at 68° F (20° C)
0.012" - 0.022" (0.30 - 0.55 mm)
0.024" (0.60 mm)
0.039" - 0.047" (1.00 - 1.20 mm)
0.049" (1.25 mm)
0.008" - 0.028" (0.20 - 0.70 mm)
0.029" (0.75 mm)
0.0006" - 0.0024" (0.015 - 0.060 mm)
0.0006" - 0.0024" (0.015 - 0.060 mm)
0.7886" + 0.000 / - .015" (20.030 + .000 / - .015
mm)
0.00098" ± .0004" (0.025 ± 0.010 mm)
0.012" ± 0.0039" (0.30 ± .10 mm)
0.0098" - .0023" (0.025 - .059 mm)
Refer to procedure.
Less than .001" (0.025 mm)
Less than .001" (0.025 mm)
2.1642" - 2.1649" (54.97 - 54.99 mm)
1.7718" - 1.7726" (45.005 - 45.025 mm)
9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
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