3.58
9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual
© Copyright Polaris Industries Inc.
PISTON-TO-CYLINDER CLEARANCE
Measure piston outside diameter at a point 10 mm
q
up
from the bottom of the piston, at a right angle to piston
pin bore.
Subtract measurement from maximum measurement
obtained in Step 4 of Cylinder Inspectionpage
3.54“Cylinder Inspection” procedure.
MEASUREMENT
Piston O.D. (Standard):
3.6597 ± .0003" (92.959 ± 0.008 mm)
Piston to Cylinder Clearance:
.0009 - .0019" (0.025 - 0.050 mm)
CONNECTING ROD INSPECTION
1. The 3 digit numbers stamped onto the intake side of
the connecting rod are serial numbers used to match
the rod cap
w
with the rod stem
e
.
2. The number
r
and letter
t
stamped onto the
exhaust side of the connecting rod represent the
bore diameter and weight grading of the connecting
rod.
3. Inspect the small end and big end of connecting rod
(and matching rod cap) for damage, galling of
surface or pitting.
4. Measure small end I.D. in two directions as shown.
Record measurements and compare to
specifications. Replace connecting rod if worn past
the service limit specification.
MEASUREMENT
Connecting Rod Small End I.D.:
.7879 - .7885" (20.015 - 20.030 mm)
Service Limit:
.7897" (20.06 mm)
5. Install matching rod cap on connecting rod (without
bearings) and install the bolts.
6. Tighten bolts snug, then torque to 13 ft-lbs (18 Nm).
ENGINE / COOLING SYSTEM
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