Polaris 2007 Sportsman 500 EF Service Manual page 63

Engine Service Data
Cylinder / Piston / Connecting Rod
Cylinder Surface warpage limit (mating with cylinder
head)
Cylinder bore
Taper limit
Out of round limit
Piston clearance
Boring Limit
Piston Outer diameter
Standard inner diameter of piston pin bore .9055-.9057" (23.0-23.006 mm)
Piston Pin Outer diameter
Standard clearance-piston pin to pin bore .0002-.0003" (.004-.008 mm)
Degree of fit
Piston Ring Piston Ring Installed
gap
Piston Ring Standard clearance -
piston ring to ring
groove
Connecting Connecting rod small end ID
Rod
Connecting rod small end radial
clearance
Connecting rod big end side
clearance
Connecting rod big end radial
clearance
Crankshaft Crankshaft runout limit
KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side;
PTO: Power Take Off.
.0020" (0.05 mm)
Std 3.6221-3.6228" (92.00-92.02 mm)
.0020" (0.05 mm)
.0020" (0.05 mm)
Std .0006-.0018" (0.015-0.045 mm)
Limit .0024" (0.060 mm)
.020" (.5 mm)
Std 3.6204-3.6215" (91.970-91.985mm)
.0098" (.25 mm) OS 3.6304-3.6310" (92.21-92.23 mm)
.0197" (.50 mm) OS 3.6403-3.6407" (92.46-92.47 mm)
.9053-.9055" (22.994-23.0 mm)
Piston Pin must be a push (by hand) fit at 68
Top ring Std .0079-.0138" (.20-.36 mm)
Limit .039" (1.0 mm)
Second Std .0079-.0138" (.20-.36 mm)
ring
Limit .039" (1.0 mm)
Oil ring Std .0079-.0276" (0.20-0.70 mm)
Limit .059" (1.5 mm)
Top ring Std .0016-.0031" (0.040.-080 mm)
Limit .0059" (.15 mm)
Second Std .0012-.0028" (0.030-0.070 mm)
ring
Limit .0059" (.15 mm)
.9058- .9063" (23.007 - 23.020 mm)
Std .0003-.0010" (.007-.026 mm)
Limit .0020 (.05 mm)
Std .0039-.0256" (.1-.65 mm)
Limit .0315" (.80 mm)
Std .0004-.0015" (.011-.038 mm)
Limit .0020" (.05 mm)
.0024" (.06 mm)
ENGINE
EH50PLE
o
F (20
3
o
3.5