Connecting Rod Inspection - Polaris Sportsman XP 1000 S 2020 Service Manual

CONNECTING ROD INSPECTION

1. Secure connecting rod lightly in a soft jawed vise.
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2. Remove piston circlip .
NOTICE
Notice the location of the piston circlip gap at top.
3. Push piston pin out of piston. If necessary, heat
crown of piston slightly with a propane torch or heat
gun.
IMPORTANT
Do not apply heat to piston rings or a loss of radial
tension could result.
4. Measure piston pin O.D. in two directions and 3
locations on the length.
MEASUREMENT
Piston Pin O.D. :
0.7873 ± .0001" (19.9975 ± .0025 mm)
5. Inspect small end and big end of connecting rod (and
matching rod cap) for damage, galling of surface or
pitting.
9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc.
ENGINE / COOLING SYSTEM
6. Measure small end I.D. in two directions as shown.
Record measurements. The difference between
measurements is concentricity. Compare to
specifications.
MEASUREMENT
Connecting Rod (Small End) Diameter:
0.7886 + 0.0 / - .015" (20.03 + 0.0 / - .015 mm)
Connecting Rod (Small End) Concentricity:
< 0.00027" (0.007 mm) Out Of Round
7. Install matching rod cap on connecting rod (without
bearings). Lubricate bolt threads and install the bolts.
8. Torque bolts to specification.
TORQUE
Connecting Rod Bolts: For Measurement
16 ft-lbs (22 N·m)
9. Using a dial bore gauge, measure big end I.D. in two
directions shown. Record measurements. Difference
between measurements is concentricity. Compare to
specifications.
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