Polaris 2012 Sportsman Forest 500 International, Service Manual

Page: 62 / 432

3.7
ENGINE
3
9923412 - 2012 Sportsman 400/500 and EFI Tractor Service Manual
© Copyright 2011 Polaris Sales Inc.
Sportsman 400 H.O. Engine Service Data (EH46PLE 455cc Carbureted)
KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side;

PTO: Power Take Off Side.
Cylinder / Piston / Connecting Rod EH46PLE (455cc)
Cylinder
Surface warpage limit (mating with cylinder head) .0020” (0.05 mm)
Cylinder bore Std 3.4606-3.4614" (87.90-87.92 mm)
Taper limit .0020” (0.050 mm)
Out of round limit .0020” (0.050 mm)
Piston clearance
Std .0006-.0020" (0.015-0.050 mm)
Limit .0024" (0.060 mm)
Boring Limit .020” (.5 mm)
Piston
Outer diameter
Std 3.4594-3.4600" (87.870-87.885 mm)
.0098" (.25 mm) OS 3.4693-3.4699" (88.120-88.135 mm)
.0197" (.50 mm) OS 3.4791-3.4797" (88.370-88.385 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
o
F (20
o
C)
Piston Ring Piston Ring Installed gap
Top ring
Std .0079-.0138" (.20-.35 mm)
Limit .039" (1.0 mm)
Second
ring
Std .0079-.0138" (.20-.35 mm)
Limit .039" (1.0 mm)
Oil ring
Std .0079-.0236" (.20-.60 mm)
Limit .059" (1.5 mm)
Piston Ring
Standard clearance -

piston ring to ring groove
Top ring
Std .0016-.0031" (.040-.080 mm)
Limit .0059" (.15 mm)
Second
ring
Std .0012-.0028" (.030-.070 mm)
Limit .0059" (.15 mm)
Connecting Rod
Connecting rod small end ID .9058 - .9063” (23.007 - 23.020 mm)
Connecting rod small end radial clearance
Std .0003-.0010" (.007-.026 mm)
Limit .0020" (.05 mm)
Connecting rod big end side clearance
Std .0035-.0197" (.09-.50 mm)
Limit .0315" (.80 mm)
Connecting rod big end radial clearance
Std .0004-.0015" (.011-.038 mm)
Limit .0020" (.05 mm)
Crankshaft Crankshaft runout limit .0024" (.06 mm)