2009 Polaris Sportsman 850 XP EFI EPS Service Manual, Page 98Get this manual
ENGINE CYLINDERPISTON (IN MM) CylinderSurface warp limit (mating with cylinder head) Cylinder Cylinder BoreStandard Cylinder Out of Round Limit Cylinder to Piston Clearance Piston PistonStandard O.D- Measured 90 degrees to pin, 1.3 in(33.0 mm) down from piston crownPiston Pin Bore I.D(Standard) Piston Pin Outside Diameter Piston Pin Piston PinStandard ClearancePiston Pin to Pin Bore Piston PinDegree of Fit 0.004" (0.10 mm) 3.4252" .0021" 3.4231" 0.7877" 0.7873" 0.0004" .0005 (87 mm .0013" (.053 .01mm)
0.0003" (0.0075 mm) .03mm) .02 mm) .004 mm) .0025 mm) 0.0065 mm)
.0008" (86.947 .0002" (20.007 .0001" (19.9975 .0002" (0.0095
Piston pin must be push fit (by hand) at 68 (20 C)
PISTONRINGSCONNECTING RODCRANKSHAFT (IN MM) Top RingStandard Top RingService Limit Installed Gap Piston Ring Second RingStandard Second RingService Limit Oil Ring RailsStandard Oil Ring RailsService Limit Ring to Groove Clearance Top RingStandard Second RingStandard 0.008"0.014" (0.200.36 mm) 0.016" (0.41 mm) 0.014"0.024" (0.360.61 mm) 0.032" (0.81 mm) 0.020" 0.0024" 0.0028" 0.010" (0.51 0.25 mm) 0.020 mm) 0.020 mm) 0.032" (0.81 mm) 0.0008" (0.060 0.0008" (0.070