2008 Polaris ATV Sportsman 300 400 H.O. Service Manual, Page 54Get this manual
ENGINE (300) Engine Service Data
CylinderPistonConnecting Rod
Surface warpage limit (mating with cylinder head) Cylinder bore Std Cylinder Taper or Out-of-Round Limit Piston to cylinder clearance Boring Limit Std Piston Outer diameter Pin BoreInner Diameter Pin outer diameter clearance in piston Piston Pin Degree of fit Top ring Piston Ring Installed Gap Second ring Oil ring Piston Ring Top ring Piston Ring to Ring Groove Second Clearance ring Oil ring Connecting rod small end ID Connecting rod small end radial clearance (to piston pin) Connecting rod big end axial (side) clearance Std Limit Std Limit Std Limit Std Limit Std Limit Std Limit Std Limit Std Limit Std Limit 1st O.S2nd O.SLimit Std Limit
ES300PFE012
.002" (0.05 mm) 3.0590-3.0598" (77.70-77.72 mm) .002" (0.05 mm) .0015-.0032" (0.038-0.082 mm) .0043" (0.11 mm) 1st O.S+ .0098" (.25 mm) 2nd O.S+ .0197" (.50 mm) 3.0566-3.0575" (77.638-77.662 mm) .0098" (.25 mm) Oversize .0197" (.50 mm) Oversize .7089-.7094" (18.007-18.020 mm) .00015- .00047" (.004- .012 mm) Push (by hand) fit 68o (20o C) (Standard clearance 0-.0005" (0-.012mm) .008-.0012" (.2-.3 mm) .032" (.8 mm) .018-.019" (.35-.50 mm) .039" (1.0mm) .0079-.0275" (.2-.7 mm) .059" (1.5 mm) .0006-.0029" (.015.074 mm) .006" (.15 mm) .0009-.0025" (.025-.065 mm) .006" (0.15 mm) .002-.0057" (.055-.145 mm) NA .7089-.7094" (18.007-18.020 mm).0007" (00.019 mm) .0011" (.03 mm) .0035-.0196" (.09-.50 mm) .023" (.60 mm) 0.0004-.0014" (.011-0.038 mm) .0019" (.05 mm)