Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 62 / 289

GENERAL INFORMATION
3.4
EH50PLE10 ENGINE SERVICE DATA
Cylinder / Piston / Connecting Rod EH50PLE10
Cylinder Surface warpage limit (mating with
cylinder head)
.0020
″
(.05 mm)
Cylinder bore Std 3.6221-3.6228
″
(92.00-92.02 mm)
Taper limit .0020
″
(.050 mm)
Out of round limit .0020
″
(.050 mm)
Piston clearance
Std .0006-.0018
″
(.015-.045 mm)
Limit .0024
″
(.060 mm)
Boring limit .020
″
(.5 mm)
Piston Outer diameter
Std 3.6204-3.6215
″
(91.970-91.985 mm)
.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)
Standard inner diameter of piston
pin bore
.9055-.9057
″
(23.0-23.006 mm)
Piston Pin
Outer diameter .9053-.9055
″
(22.994-23.0 mm)
Standard clearance-piston pin to pin
bore
.0002-.0003
″
(.004-.008 mm)
Degree of fit Piston pin must be a push (by hand) fit
at 68
°
F (20
°
C)
Piston Ring Piston ring installed Top
Std .0079-.0138
″
(.20-.36 mm)
g g
gap
p
ring
Limit .039
″
(1.0 mm)
Second Std
.0079-.0138
″
(.20-.36 mm)
ring
Limit .039
″
(1.0 mm)
Oil ring Std
.0079-.0276
″
(.20-.70 mm)
g
Limit .059
″
(1.5 mm)
Piston Ring Standard clearance Top
Std .0016-.0031
″
(.040-.080 mm)
g
-
piston ring to ring
p
ring
Limit .0059
″
(.15 mm)
piston ring to ring
groove
Second Std
.0012-.0028
″
(.030-.070 mm)
groove
ring
Limit .0059
″
(.15 mm)
Connecting Connecting rod small end ID .9058-.9063
″
(23.007-23.020 mm) g
Rod
Connecting rod small end ra- Std .0003-.0010
″
(.007-.026 mm) g
dial clearance
Limit .0020
″
(.05 mm)
Connecting rod big end side Std .0039-.0256
″
(.1-.65 mm) g g
clearance
Limit .0315
″
(.80 mm)
Connecting rod big end radial Std .0004-.0015
″
(.011-.038 mm) g g
clearance
Limit .0020
″
(.05 mm)
Crankshaft Crankshaft runout limit .0024
″
(.06 mm)
KEY - Std: Standard; OS: Oversize; ID: Inner Diameter;
OD: Outer Diameter; Mag: Magneto Side; PTO: Power
Take Off Side