Connecting Rod Big End Bearing Selection; Piston / Piston Ring Inspection; Piston Ring Removal - Polaris 2009 Sportsman XP 850 Service Manual

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.
Paint mark
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).
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
47.987mm
Con Rod Big End
-
Bore Diameter
47.993mm
Target Oil Clearance
(Con Rod Bearing)
Bearing color to
Red
install
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
1.8892 in.
Con Rod Big End
-
Bore Diameter
1.8895 in.
Target Oil Clearance
(Con Rod Bearing)
Bearing color to
Red
install
5.48
White Blue Yellow
47.993mm 47.999mm 48.005mm
- - -
47.999mm 48.005mm 48.011mm
.023 mm - .057 mm
White Blue Yellow
White Blue Yellow
1.8895 in. 1.8897 in. 1.8899 in.
- - -
1.8897 in. 1.8899 in. 1.8902 in.
.0009 in. - .0022 in.
White Blue Yellow

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.
B

Piston Ring Removal

1. Carefully remove top compression ring by hand or using a
ring removal pliers.
NOTICE
Do not expand the ring more than necessary to remove
it from piston or ring may break or lose radial tension.
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.
A
C