Piston / Rod Inspection; Piston Ring Installed Gap - Polaris Ranger 500 2x4 2007 Service Manual

ENGINE

Piston / Rod Inspection

1. Measure piston pin bore.
Piston Pin Bore
Piston Pin Bore:
.9055 - .9057" (23.0 - 23.006 mm)
2. Measure piston pin O.D. Replace piston and/or piston pin
if out of tolerance.
Piston Pin Measurement Locations
Piston Pin O.D.
.9053 - .9055" (22.994 - 23.0 mm)
3. Measure connecting rod small end ID.
3.32
4. Measure piston ring to groove clearance by placing the ring
in the ring land and measuring with a thickness gauge.
Replace piston and rings if ring-to-groove clearance
exceeds service limits.
Piston Ring-to-Groove Clearance
Top Ring Std: .0016-.0031" (.040-.080 mm)
Limit: .0059" (15 mm)
Second Ring Std: .0012-.0028" (.030-.070 mm)
Limit: .0059" (15 mm)

Piston Ring Installed Gap

1. Place each piston ring inside cylinder using piston to push
ring squarely into place as shown at right.
2. Measure installed gap with a feeler gauge at both the top
and bottom of the cylinder.
Cylinder
Piston ring
Piston Ring Installed Gap
Top Ring
Std: .0079-.0138" (.20-.36 mm)
Limit: .039" (1.0 mm)
Second Ring
Std: .0079-.0138" (.20-.36 mm)
Limit: .039" (1.0 mm)
Oil Ring
Std: .0079-.0276" (.20-.70 mm)
Limit: .059" (1.5 mm)
Piston
Ring
Feeler Gauge
Feeler Gauge
25-50 mm