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ENGINE
3.33
3. Inspect cylinder for wear, scratches, or damage.
4. Inspect cylinder for taper and out of round with a
telescoping gauge or a dial bore gauge. Measure
in two different directions, front to back and side to
side, on three different levels (1/2″ down from top,
in the middle, and 1/2″ up from bottom).
1/2″ Down From Top of Cylinder
1/2″ Up From Bottom
X
X
Y
Y
X
Y
5. Record measurements. If cylinder is tapered or
out of round beyond .002, the cylinder must be
replaced.
Cylinder Taper
Limit: .002I (.05mm)Max.
Cylinder Out of Round
Limit: .002I (.05mm)Max.
Standard Bore Size (Both Cylinders):
Sportsman 700 / 800 : 3.1496I (80 mm)
PISTON-TO-CYLINDER
CLEARANCE
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.
Subtract this measurement from the maximum
cylinder measurement obtained in Step 5.
5mm
Piston
Piston Pin
Piston to Cylinder Clearance
Refer To Engine Service Data
Pg. 3.12 -- 3.14
Piston O.D.
Refer To Engine Service Data
Pg. 3.12 -- 3.14