Cylinder Inspection; Piston Removal - Polaris RANGER 500 2017 Service Manual

ENGINE / COOLING SYSTEM
2. Position the cam chain and guides vertically.
3. Tap cylinder lightly with a plastic hammer in the
reinforced areas only until loose.
4. Rock cylinder forward and backward and lift it from
the crankcase, supporting piston and connecting rod.
5. Remove the cylinder from the engine.
6. Remove and discard cylinder base gasket.
NOTICE
Stuffing a clean rag around the connecting rod after
cylinder is removed is helpful in keeping foreign objects
from falling into the crankcase.

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:
.00098" (.025 mm)
3.56
3. Inspect cylinder for wear, scratches, or damage.
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).
5. Record measurements taken in Step 4. If cylinder is
tapered, or out of round beyond .001, cylinder must
be re-bored oversize, or replaced.
Cylinder Taper Limit:
.001" Max. (0.025 mm)
Cylinder Out of Round Limit:
.001" Max. (.025 mm)
Standard Bore Size:
3.6614 +/- 0.0003" (93.0 +/- 0.008 mm)

PISTON REMOVAL

1. Ensure the piston arrow points toward the exhaust
side of the engine.
2. Remove piston circlip and push piston pin out of
piston. If necessary, heat the crown of the piston
slightly with a heat gun.
IMPORTANT
Do not apply heat to the piston rings, they may lose
radial tension.
9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual
© Copyright Polaris Inc.