cylinder bore? help - Polaris ATV Forum
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post #1 of 8 (permalink) Old 08-07-2013, 02:52 PM Thread Starter
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cylinder bore? help

ok im about to buy a cylinder and piston for my polaris sportsman 500 and the guy says its bored .50 over with a wesco piston of 92.50 im wanting to know what should the cylinder walls measure to make sure its bored right before i buy it thank.
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post #2 of 8 (permalink) Old 08-07-2013, 08:16 PM
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You need to have the piston on hand to bore the cylinder to the correct size to fit the exact piston you are putting in. Need to measure the cylinder at it's current bore and then order accordingly and final hone to spec.
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post #3 of 8 (permalink) Old 08-07-2013, 08:28 PM
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^ Well said.

Cylinder Surface warpage limit (mating with cylinder
head)
.0020” (0.05 mm)
Cylinder bore Std 3.6221-3.6228” (92.00-92.02 mm)
Taper limit .0020” (0.05 mm)
Out of round limit .0020” (0.05 mm)
Piston clearance Std .0006-.0018" (0.015-0.045 mm)

2009 850 EPS - 2500 miles and counting
2009 550 EPS - 8200 miles and counting
2006 500 EFI - 18,700 miles and *SOLD*
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post #4 of 8 (permalink) Old 08-08-2013, 02:15 AM Thread Starter
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Its already bored according to the piston he's got 92.5 just want to know how to make sure its bored correctly
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post #5 of 8 (permalink) Old 08-08-2013, 03:52 AM
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Snap gauges and a micrometer
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post #6 of 8 (permalink) Old 08-08-2013, 05:03 AM Thread Starter
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I know that but what is the measurement that the cylinder is spouse to differ from the piston?
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post #7 of 8 (permalink) Old 08-08-2013, 11:48 AM
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That's on the service manual or the box with the piston. Varies on cylinder wall material and piston type. Looks like turboshelby already put that info up for you.
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post #8 of 8 (permalink) Old 08-08-2013, 03:56 PM
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That info is wrong for a Wiseco piston. Should be a lot more piston to wall clearance with the forged Wiseco. With a Wiseco you are gonna want 3.5 to 5 thousandths depending on the motor and its use. If you use the piston to wall clearance in the service manual you will have a seized motor in no time. It will be far too tight.
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