Polaris 2009 Sportsman XP 850 User Manual

5.48
ENGINE
Connecting Rod Big End Bearing Selection
1. If using NEW connecting rods, install the bearing color
that matches the color marked on the connecting rod cap as
shown below.
2. If re-installing the original connecting rod, select the
appropriate bearing from the table below based on
connecting rod big end I.D. measurements (page 5.47).
Piston / Piston Ring Inspection
1. Measure piston ring to ring land clearance with a thickness
gauge (A) inserted between bottom edge of ring (B) and
piston ring land (C). Replace both piston and rings if
clearance exceeds service limit.
2. Repeat for 2nd ring.
Piston Ring Removal
1. Carefully remove top compression ring by hand or using a
ring removal pliers.
Piston ring pliers: Carefully expand ring and lift it off the
piston.
By hand: Placing both thumbs as shown, spread the ring open
and push up on opposite side. Do not scratch ring lands.
2. Repeat procedure for second ring.
3. Remove (3 piece) oil control ring. Remove top rail first,
then bottom rail, then the expander.
Bearing Size Selection Chart In Millimeters
Connecting rod journal must be within standard size limits as
determined by crankshaft measurements (See page 5.46).
Con Rod Mark Red White Blue Yellow
Con Rod Big End
Bore Diameter
47.987mm
-
47.993mm
47.993mm
-
47.999mm
47.999mm
-
48.005mm
48.005mm
-
48.011mm
Target Oil Clearance
(Con Rod Bearing)
.023 mm - .057 mm
Bearing color to
install
Red White Blue Yellow
Bearing Size Selection Chart In Inches
Connecting rod journal must be within standard size limits as
determined by crankshaft measurements (See page 5.46).
Con Rod Mark Red White Blue Yellow
Con Rod Big End
Bore Diameter
1.8892 in.
-
1.8895 in.
1.8895 in.
-
1.8897 in.
1.8897 in.
-
1.8899 in.
1.8899 in.
-
1.8902 in.
Target Oil Clearance
(Con Rod Bearing)
.0009 in. - .0022 in.
Bearing color to
install
Red White Blue Yellow
Paint mark
NOTICE
Do not expand the ring more than necessary to remove
it from piston or ring may break or lose radial tension.
A
B
C
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Polaris 2009 Sportsman XP 850 Specifications

General

Brand	Polaris
Model	2009 Sportsman XP 850
Category	Offroad Vehicle
Language	English