Polaris PREDATOR 2003, Service Manual

Page: 47 / 193

ENGINE
3.4
ES50PL ENGINE SERVICE DATA
Valve Spring Overall length Inner 1.575
s
(40.0 mm)
Limit = --.079
s
(--2.0 mm) Outer
1.650
s
(41.9 mm)
Squareness Inner .067-
s
(1.7 mm) q
Outer .071
s
(1.8 mm)
Cylinder / Piston / Connecting Rod EH50PL12
Cylinder Surface warpage limit (mating with
cylinder head)
.002
s
(.05 mm)
Cylinder bore Std 3.9055-3.9062
s
(99.20-99.22 mm)
Taper limit .002
s
(.05 mm)
Out of round limit .002
s
(.05 mm)
Piston clearance
Std .0018-.0025
s
(.046-.065 mm)
Limit .0039
s
(.10 mm)
Piston
Outer diameter Std 3.9037-3.904
s
(99.155-99.170 mm)
Piston Pin Bore Standard I.D. .9055-.9057
s
(23.001-23.007 mm)
Piston Pin
Outer diameter .9053-.9055
s
(22.996-23.0 mm)
Piston pin to pin bore clearance .0002-.0004
s
(.001-.0011 mm)
Degree of fit Piston pin must be a push (by hand) fit at
68
q
F (20
q
C)
Piston Ring to ring groove clearance Top Std .0012-.0028
s
(.030-.070 mm) g g g p
ring
Limit .0059
s
(.15 mm)
Second Std .0012-.0028
s
(.030-.070 mm)
ring
Limit .0059
s
(.15 mm)
Piston Ring installed gap Top Std .008-.012
s
(.20-.30 mm) g g p p
ring
Limit .027
s
(.7 mm)
Second Std .014-.019
s
(.35-.50 mm)
ring
Limit .031
s
(.8 mm)
Oil ring Std .004-.019
s
(.10-.50 mm) g
Limit .039
s
(1.0 mm)
Connecting
Connecting rod small end ID .9058-.9063
s
(23.007-23.020 mm)
g
Rod
Connecting rod small end
Std .0003-.0009
s
(.007-.024 mm)
g
radial clearance
Limit .0020
s
(.05 mm)
Connecting rod big end side Std
.0035-.0196
s
(.09-.50 mm)
g g
clearance
Limit .0255
s
(.65 mm)
Connecting rod big end
Std .0004-.0015
s
(.011-.038 mm)
g g
radial clearance
Limit Same as standard
Crankshaft Crankshaft runout limit .0024
s
(.06 mm)
KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side; PTO: Power
Take Off Side
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