2008 Polaris ATV Predator 50, Sportsman Outlaw 90 Service Manual, Page 51Get this manual
ENGINETRANSMISSION Engine Service Data
CylinderPistonConnecting Rod Sportsman 90Outlaw 90
Surface warpage limit (mating with cylinder head) .002" (0.05 mm) Cylinder bore Taper limit Cylinder Out of round limit Piston to cylinder clearance Boring Limit Std Outer diameter (Measure 5mm up from 1st O.Sbottom and 90 to piston pin) 2nd O.SPin Bore Pin to piston pin bore clearance Piston Pin Std Limit Std 1.85041.8507" (47.0047.01 mm) .002" (0.05 mm) .002" (0.05 mm) .0004.0014" (0.010.04 mm) .0039" (0.1 mm) 2nd Oversize (+ .0197".50 mm) 1.84921.8500" (46.9746.99 mm) .0098" (.25 mm) Oversize .0197" (.50 mm) Oversize .5122.5129" (13.0113.03 mm) .0002.0005" (.004.012 mm) Degree of fit Piston Pin must be push (by hand) fit at 68 (20 C) Pin Diameter .5117.5118" (12.997-13.00mm) (Limit: 12.96mm) Top ring Piston Ring Piston Ring Installed gap Second ring Oil ring Top ring Piston Ring Standard clearance piston ring to ring groove Second ring Std Limit Std Limit Std Limit Std Limit Std Limit Std Limit Std Std .002.008" (.10.25 mm) .020" (0.5 mm) .002.008" (.30.45 mm) .020" (0.5mm) .012.035" (0.20.7 mm) .059" (1.5 mm) .0008.0024" (0.02- 06 mm) .0035" (0.09 mm) .0008.0024" (0.020.06 mm) .0035" (0.09 mm) .5122".5129" (13.0113.03 mm) .5141" (13.06 mm) .004.012" (0.10.3 mm) .0002.0005" (0.0020.013 mm) 0.0016" (0.04 mm) 0.0039" (0.1 mm) Install new as part of any oil pump replacement Cam Shaft Chain KEYStd: Standard; OS: Oversize; ID: Inner Diameter; OD: Outer Diameter; Mag: Magneto Side; PTO: Power Take Off