2009 Polaris Sportsman 850 XP EFI EPS Service Manual, Page 139Get this manual
ENGINE Connecting Rod Inspection
12Secure connecting rod lightly in soft jawed viseNote location of the piston circlip gap (A) at top7Measure small end I.Din two directions as shownRecord measurementsDifference between measurements is concentricityCompare to specifications
Connecting Rod (Small End) Diameter: 0.78860.0- .015" (20.030.0- .015 mm) Connecting Rod (Small End) Concentricity: 0.00027" (0.007 mm) Out Of Round
89Do not apply heat to piston rings or loss of radial tension could result5Measure piston pin O.Din two directions and locations on the lengthInstall matching rod cap on connecting rod (without bearings) and install boltsTighten bolts snug, then torque to 24 lb-ft (33 Nm)
Remove piston circlipPush piston pin out of pistonIf necessary, heat crown of piston slightly with propane torch or heat gun