Polaris TRAIL BOSS 325 2001, Manual

Page: 60 / 296

ENGINE
3.4
ES32PFE ENGINE SERVICE DATA
Cylinder / Piston / Connecting Rod ES32PFE
Cylinder Surface warpage limit (mating with cylinder head) .0020
s
(0.050 mm) y
Cylinder bore Std 3.0732-3.0740
s
(78.000-78.020 mm)
Taper limit .0020
s
(0.050 mm)
Out of round limit .0020
s
(0.050 mm)
Piston clearance Std .0015-.0032
s
(0.038-0.082 mm)
Limit .004
s
(0.11 mm)
Boring limit .0020
s
(0.5 mm)
Piston Outer diameter Std 3.0707-3.0717
s
(77.938-77.962 mm)
.0098
s
(.25 mm) OS 3.0806-3.0815
s
(78.188-78.212 mm)
.0197
s
(.50 mm) OS 3.0905-3.0914
s
(78.438-78.462 mm)
Standard inner diameter of piston pin bore .7095-.7097
s
(18.007-18.013 mm)
Piston Pin Outer diameter .7092--.7095
s
(18.001-18.007 mm)
Standard clearance-piston pin to pin bore 0.0-.0005
s
(0.0-0.012 mm)
Degree of fit Piston pin must be a push (by hand)
fit at 68
q
F (20
q
C)
Piston Ring Piston ring installed gap Top ring
Std .0079-.0138
s
(0.20-0.35 mm)
g g g p p g
Limit .039
s
(1.0 mm)
Second
i
Std .0138-.0197
s
(0.35-0.50 mm)
ring
Limit .039
s
(1.0 mm)
Oil ring
Std .0079-.0276
s
(0.20-0.70 mm)
g
Limit .059
s
(1.5 mm)
Piston Ring Standard clearance -
i i i
Top ring Std .0014-.0030
s
(0.035-0.075 mm) g
piston ring to ring groove
p g
Limit .0059
s
(0.15 mm)
Second
i
Std .0010-.0026
s
(0.025-0.065 mm)
ring
Limit .0059
s
(0.15 mm)
Connecting
R d Connecting rod small end ID .7095-.7101
s
(18.007-18.023 mm) g
Rod
Connecting rod small end radial clear-
Std 0.0-.0009
s
(0.0-0.022 mm)
g
ance
Limit .0012
s
(0.03 mm)
Connecting rod big end side clearance Std .0028-.0118
s
(0.07-0.30 mm) g g
Limit .0138
s
(0.35 mm)
Connecting rod big end bearing clear-
Std 0.0007-0.0021
s
(0.019-0.053 mm)
g g g
ance
Limit 0.0026
s
(0.065 mm)
Crankshaft Crankshaft runout limit (PTO end) 0.0024
s
(0.060 mm)
Crankshaft end play 0.002-0.008
s
(0.05-0.20 mm)
KEY - Std: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side; PTO: Power
Take Off Side