Piston Disassembly / Inspection - Polaris RANGER 1000 2020 Service Manual

ENGINE / COOLING / EXHAUST

PISTON DISASSEMBLY / INSPECTION

NOTICE
New pistons are directional (intake vs. exhaust), but
can be placed in either cylinder.
1. Note location of the piston circlip gap
(12:00 position) or bottom (6:00 position).
2. Remove piston circlip and push piston pin out of
piston. If necessary, heat the crown of the piston
slightly with a heat gun if pin cannot be removed by
hand. Discard circlips.
DO NOT apply heat to piston rings or a loss of radial
tension could result.
3.66
q
at the top
CAUTION
3. Measure piston pin bore I.D. in two directions (90°
apart). Replace piston and piston pin if out of
specification.
MEASUREMENT
Piston Pin Bore I.D.:
0.7876 - 0.7878" (20.005 - 20.009 mm)
Service Limit:
.7893" (20.05 mm)
4. Measure piston pin O.D. in two directions (90° apart)
at three locations on the length. Replace piston and
piston pin if out of specification.
MEASUREMENT
Piston Pin O.D.:
0.7872 - 0.7874" (19.995 - 20.004 mm)
Service Limit:
0.7864" (19.975 mm)
9850045 R01 - 2020-2021 RANGER 1000 Service Manual
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