Polaris TRAIL BOSS 2003 User Manual

ENGINE
3.24
CYLINDER INSPECTION CONT’D
5. Record measurements. If cylinder is tapered or
out of round beyond .002, the cylinder must be
re-bored oversize, or replaced.
Cylinder Taper
Limit: .002 Max.
Cylinder Out of Round
Limit: .002 Max.
Standard Bore Size:
3.0906-3.0913I (78.50-78.520 mm)
PISTON INSPECTION
1. Measure piston outside diameter at a point 5 mm
up from the bottom of the piston at a right angle to
the direction of the piston pin.
5mm
Piston
Piston Pin
2. Subtract this measurement from the maximum
cylinder measurement obtained in Step 5.
Piston to Cylinder Clearance
Std: .0015-.0032I (.038-.082 mm)
Limit: .004I (.11 mm)
Piston O.D.:
Std: 3.0881-3.0891I (78.438-77.462 mm)
3. Measure piston pin bore.
Piston Pin Bore:
.7095-.7097I (18.007-18.013 mm)
4. Measure piston pin O.D. Replace piston and/or
piston pin if out of tolerance.
Piston Pin Measurement Locations
Piston Pin O.D.
.7092-.7095I (18.001-18.007 mm)

Polaris TRAIL BOSS 2003 Specifications

General

Brand	Polaris
Model	TRAIL BOSS 2003
Category	Offroad Vehicle
Language	English