Piston Ring Installed Gap; Honing To Oversize - Polaris RANGER 500 2018 Service Manual

PISTON RING INSTALLED GAP

1. Place each piston ring inside cylinder. Use a piston
to push the ring squarely into place 1" (25.4 mm)
down from the cylinder head gasket surface.
2. Measure installed gap with a feeler gauge at location
q
.
Piston Ring Installed Gap
Top Ring:
Std: 0.0059 - 0.0122" (0.15 - 0.31 mm)
Limit: 0.0137" (0.35 mm)
Second Ring:
Std: 0.0094 - 0.0196" (0.24 - 0.50 mm)
Limit: 0.022" (0.56 mm)
Oil Ring Rails:
Std: 0.0098" - 0.0401" (0.25 - 1.02 mm)
Limit: 0.0480" (1.22 mm)
NOTE
Always check piston ring installed gap after re-boring a
cylinder or when installing new rings.
9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual
© Copyright Polaris Industries Inc.
ENGINE / COOLING SYSTEM

HONING TO OVERSIZE

CAUTION
If cylinder wear or damage is excessive, it will be
necessary to oversize the cylinder using a new
oversized piston and rings. This may be accomplished
by either boring the cylinder and then finish honing to
the final bore size, or by rough honing followed by finish
honing.
CAUTION
For oversize honing always wet hone using honing oil
and a coarse roughing stone. Measure piston (see
piston measurement) and calculate finished bore size.
Always leave .002 - .003" (.05 - .07 mm) for finish bore
sizing with a fine stone.
A finished cylinder should have a 45 degree cross-hatch
pattern to ensure piston ring seating, aid in oil retention
and reduce ring vibration during initial break-in. Hone
cylinder according to hone manufacturer's instructions,
or these guidelines:
• Use a motor speed of approximately 300-500 RPM,
run the hone in and out of the cylinder rapidly until
cutting tension decreases. Remember to keep the
hone drive shaft centered (or cylinder centered on
arbor) and to bring the stone approximately 1/2" (1.3
cm) beyond the bore at the end of each stroke.
• Release the hone at regular intervals and inspect the
bore to determine if it has been cleared, and to check
piston fit.
NOTE
Do not allow cylinder to heat up during honing.
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