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  1. #1

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    1995 750 SLT being reborn: Piston - cylinder - piston ring sizes and clearances

    Hello Hulkamaniacs. First time post so go easy. Not sure if I am posting this in right folder but I need help on a How to so it's in here.

    Trying to rebuild my engine and I don't see the info I need anywhere on here.

    Tore everything down and now I'm up to reinstalling the block. I'm honed out looking good. Need to get new rings now. Don't know what size I need. My pistons have a 0.25 stamped on them so I'm assuming it's been bored before and oversized.

    I have a digital caliper and a dial bore gauge ready to go. I think I understand where to go from here but I measure my piston which I'm going to guess is going to come in at 0.25 over standard. Then I set my bore gauge just over that and take measurements of cylinder walls. From that I factor in my 0.004 clearence and then I'm lost.

    Can someone correct if I'm wrong above and point me where to go next?
    Last edited by K447; 01-13-2013 at 12:19 PM. Reason: Thread title clarification


  2. #2

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    1995 750 SLT Piston/Rings/Bore help needed.

    Sorry guys, posted this in the tech section and don't know how to delete it there. Hello Hulkamaniacs. First time post so go easy. Not sure if I am posting this in right folder but I need help on a How to so it's in here. Trying to rebuild my engine and I don't see the info I need anywhere on here. Tore everything down and now I'm up to reinstalling the block. I'm honed out looking good. Need to get new rings now. Don't know what size I need. My pistons have a 0.25 stamped on them so I'm assuming it's been bored before and oversized. I have a digital caliper and a dial bore gauge ready to go. I think I understand where to go from here but I measure my piston which I'm going to guess is going to come in at 0.25 over standard. Then I set my bore gauge just over that and take measurements of cylinder walls. From that I factor in my 0.004 clearence and then I'm lost. Can someone correct if I'm wrong above and point me where to go next?

  3. #3
    Banned User
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    You are on the right track. The .25 most likely means its .25mm oversize. Post a pic of the piston. Im sure one of us can identify it for you.

  4. #4
    BlueFishCrisis's Avatar
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    Standard rings for a 750 are 69.75 as are the pistons. If yours are marked .25, you will be looking for rings marked .25, or 70.00. Here is one source that allows you to select the size you need: http://www.atlanticjetsport.com/inde..._detail&p=2909 .

    This link will provide you with a ton of useful information including steps on reassembling your motor: http://polarispwcknowledge.shorturl.com/

  5. #5

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    Dec 2012
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    Kankakee, Il,
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    That's what I was thinking. Then when I measured my piston, at its widest point it was 2.748" or 69.80 mm. Do I need to measure out my jugs to check for wear?

  6. #6
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    I would yes.

  7. #7

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    Click image for larger version. 

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  8. #8

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    Ok so I measure my piston, set that number to my bore gauge then I see where that is in the cylinder. Then I get lost

  9. #9
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    The difference in the 2 measurements is your clearance.

  10. #10

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    Which is suppose to be 0.04" correct? I've never done this before obviously. Won't the rings lessen that space?

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