2005 Polaris Sportsman 400/500 Service Manual, Page 63Get this manual
ENGINE SERVICE DATA
CylinderPistonConnecting Rod
Cylinder Surface warpage limit (mating with cylinder head) Cylinder bore Taper limit Out of round limit Piston clearance Boring limit Piston Outer diameter Std .0098 (.25 mm) OS .0197 (.50 mm) OS Standard inner diameter of piston pin bore Piston Pin Outer diameter Standard clearance-piston pin to pin bore Degree of fit Piston Ring Piston ring installed gap Top ring Second ring Oil ring Piston Ring Standard clearance piston ring to ring groove Top ring Second ring Connecting Rod Connecting rod small end ID Connecting rod small end radial clearg ance Connecting rod big end side clearance Connecting rod big end radial clearg ance Crankshaft Crankshaft runout limit Std Limit Std Limit Std Limit Std Limit Std Limit Std Limit Std Limit Std Limit Std Limit Std