2008 Polaris Sportsman 500 EFI/X2/Touring/500 H.O. Service Manual, Page 89Get this manual
ENGINE 3Inspect cylinder for wear, scratches, or damage12" Down From Top of Cylinder 2Subtract this measurement from the maximum cylinder measurement obtained in Step abovePiston to Cylinder Clearance Std: .0006- .0018" (.015- .045 mm) Piston O.D Std: 3.6204- 3.6215" (91.970-91.985 mm)
PistonRod Inspection
12" Up From Bottom 4Inspect 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 1 2" up from bottom)Record measurementsIf cylinder is tapered or out of round beyond .002, the cylinder must be re-bored oversize or replacedCylinder Taper Limit: .002 MaxCylinder Out of Round Limit: .002 MaxStandard Bore Size: 3.6221-3.6228" (92.0092.012 mm)