Piston Pin Bore Inspection; Cylinder Inspection - Polaris Sportsman 850 Service Manual

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ENGINE / COOLING SYSTEM

PISTON PIN BORE INSPECTION

1. Measure piston pin bore.

Piston Pin Bore:

0.7877 ± .0002" (20.007 ± .004 mm)

1. Remove all gasket material from gasket surface.

2. Lay a straight edge across cylinders (upper

3. Use a thickness gauge to measure gap between

straightedge and gasket surface. Measure at outer

edges and center, repeating measurements with

straightedge laid diagonally.

Cylinder Warp:

0.002" (0.05 mm) Max.

Inspect cylinder for wear, scratches, or damage.

DO NOT hone the cylinders or attempt to repair a

damaged cylinder by honing.

5. Inspect taper and out of round with a dial bore

6. Measure in two directions (front to back and side to

side) on three levels and record measurements. If

cylinder is tapered or out of round beyond .001", the

crankcase must be replaced.

Cylinder Taper Limit:

.001" (.025 mm) Maximum

Cylinder Out of Round:

Limit: .001" (.025 mm) Maximum

Standard Bore Size

3.4252" ± .0005 (87 mm ± .01 mm)

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Sportsman 1000