2004 Polaris Sportsman 700 EFI ATV Service Manual, Page 73Get this manual
ENGINE 3Inspect cylinder for taper and out of round with telescoping gauge or dial bore gaugeMeasure in two different directions, front to back and side to side, on three different levels (12 down from top, in the middle, and 12 up from bottom)12 Down From Top of Cylinder Y
PISTON-TO-CYLINDER CLEARANCE
Measure piston outside diameter at point mm up from the bottom of the piston at right angle to the direction of the piston pinSubtract this measurement from the maximum cylinder measurement obtained in Step 5
Y 12 Up From Bottom 4Record measurementsIf cylinder is tapered or out of round beyond .002, the cylinder must be replacedCylinder Taper Limit: .002I (.05mm)MaxCylinder Out of Round Limit: .002I (.05mm)MaxPiston to Cylinder Clearance 700: .0016" .00063" (.041 Piston O.D700: 3.1477" .00012I (79.954 .003 mm) .016 mm) Piston Piston Pin mm