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Discussion Starter · #1 ·
I'm overhauling my '95 Polaris XLT 600 engine and I was wondering about the allowed clearance between the piston pin and piston pin bore. My Clymer manual doesn't have that data, and I can't seem to find it anywhere.
When I stick the pin in one side of the piston and try to jiggle it, I don't feel any radial movement. But when the pin is fully inserted in the bore, it can turn without much resistance.
I measured the pin and bore and the clearance is between .001-.0015

I'm a Rotax aircraft engine mechanic and I work on both 2-strokes and 4-strokes. On the Rotax aircraft 2-strokes, the clearance wear limit is .002, yet I've never seen a pin that could turn as easily as those on my Polaris.

So is my tolerance still good?
Does anyone have the dimensions (new and wear limit) for pin diameter, pin bore diameter and pin/bore clearance for those Polaris pistons?

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