I have a 1996 polaris xpress 300cc 2 stroke. Stock piston is 74.5 mm bore, I am replacing the piston with a namura piston 20 thow oversize, 75mm bore, I need to know the clearance specs to bore out the cylinder and can't find them any where, the website is not very helpfull. If any one has any helpfull information on the piston clearance specs or can point me in the right direction it would be greatly appreciated, Thanks!!

 

Manual shows piston to cylinder clearance to be between .0012-.0026. Service limit .006 When I bored and honed 2 stroke cylinders I tried to set them up around .0015-.002 final clearance. Always premix the first tank of break in fuel 50-1 along with using the oil pump. If you bypass the oil pump premix 40-1 with a good synthetic oil. A lot of piston manufacturers aren't suggesting any certain clearances just to protect them selves..