Polaris Sportsman 700 Efi 2005 Service Manual page 87

3. Inspect cylinder for wear, scratches, or damage.
4. Inspect cylinder for taper and out of round with a
telescoping gauge or a dial bore gauge. Measure
in two different directions, front to back and side to
side, on three different levels (1/2" down from top,
in the middle, and 1/2" up from bottom).
1/2" Down From Top of Cylinder
Y
X
Y
X
Y
X
1/2" Up From Bottom
5. Record measurements. If cylinder is tapered or
out of round beyond .002, the cylinder must be
replaced.
Cylinder Taper
Limit: .002I (.05mm)Max.
Cylinder Out of Round
Limit: .002I (.05mm)Max.
Standard Bore Size (Both Cylinders):
Sportsman 700 / 800 : 3.1496I (80 mm)
PISTON-TO-CYLINDER
CLEARANCE
Measure piston outside diameter at a point 5 mm up
from the bottom of the piston at a right angle to the
direction of the piston pin.
Subtract this measurement from the maximum
cylinder measurement obtained in Step 5.
5 mm
Piston
Piston to Cylinder Clearance
Refer To Engine Service Data
Pg. 3.12 - - 3.14
Piston O.D.
Refer To Engine Service Data
Pg. 3.12 - - 3.14
ENGINE
Piston Pin
3.33