Polaris Outlaw 500, Service Manual, Page: 52 / 202

3.5
ENGINE
3
ES50PL Engine Service Data
KEY – Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side; PTO: Power Take Off Side.
Cylinder / Piston / Connecting Rod / Crankshaft ES50PL
Cylinder
Surface warpage limit (mating with cylinder head) .002” (.05 mm)
Cylinder bore Std 3.9055–3.9062” (99.20–99.22 mm)
Taper limit .002” (.05 mm)
Out of round limit .002” (.05 mm)
Piston clearance
Std .0018- .0025” (.046- .065 mm)
Limit .0039” (.10 mm)
Piston
Outer diameter Std 3.9037- 3.904” (99.155- 99.170 mm)
Piston Pin Bore Standard I.D. .9055- .9057” (23.001- 23.007 mm)
Piston Pin
Outer diameter Std .9053- .9055” (23.001 - 23.007 mm)
Piston pin to pin bore clearance .0002- .0004” (.001- .0011 mm)
Degree of fit
Piston Pin must be a push (by hand)
fit at 68
o
F(20
o
C)
Piston Ring to ring groove clearance
Top
Ring
Std .0012–.0028” (.030–.070 mm)
Limit .0059” (.15 mm)
Second
Ring
Std .0012–.0028” (.030–.070 mm)
Limit .0059” (.15 mm)
Piston Ring installed gap
Top
Ring
Std .008–.012” (.20–.30 mm)
Limit .027” (.7 mm)
Second
Ring
Std .014–.019” (.35–.50 mm)
Limit .031” (.8 mm)
Oil Ring
Std .004–.019” (.10–.50 mm)
Limit .039” (1.0 mm)
Connecting Rod
Connecting rod small end ID .9058- .9063” (23.007- 23.020 mm)
Connecting rod small end radial
clearance
Std .0003- .0009” (.007- .024 mm)
Limit .0020” (.05 mm)
Connecting rod big end side clearance
Std .0035- .0196” (.09- .50 mm)
Limit .0255” (.65 mm)
Connecting rod big end
radial clearance
Std .0004- .0015” (.011- .038 mm)
Limit Same as standard
Crankshaft Crankshaft runout limit .0024” (.06 mm)