Cylinder Inspection; Piston-To-Cylinder Clearance - Polaris Ranger 500 2x4 2007 Service Manual

Cylinder Inspection

1. Remove all gasket material from the cylinder sealing
surfaces.
2. Inspect the top of the cylinder for warpage using a straight
edge and feeler gauge.
Cylinder Warpage:
.002" (.05 mm)
3. Inspect cylinder for wear, scratches, or damage.
1/2" Down From Top of Cylinder
X
X
X
1/2" Up From Bottom
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).
Y
Y
Y
5. Record measurements. If cylinder is tapered, or out of
round beyond .002, the cylinder must be re-bored oversize,
or replaced.
Cylinder Taper
Limit: .002 Max.
Cylinder Out of Round
Limit: .002 Max.
Standard Bore Size:
3.6221 - 3.6228" (92.00 - 92.012 mm)

Piston-to-Cylinder Clearance

1. Measure piston outside diameter at a point 40 mm down
from the top of the piston at a right angle to the direction
of the piston pin.
40 mm
2. Subtract this measurement from the maximum cylinder
measurement obtained in Step 5 above.
Piston to Cylinder Clearance
Std: .0006-.0018" (.015-.045 mm)
Piston O.D.:
Std: 3.6204-3.6215" (91.970-91.985 mm)
ENGINE
Piston
Piston Pin
3.31
3