Polaris 2004-2005 Sportsman 6x6 Service Manual page 89

GENERAL INFORMATION
PISTON RING INSTALLED
GAP
1. Place each piston ring inside cylinder using piston
to push ring squarely into place as shown at right.
Cylinder
Piston Ring
Piston Ring Installed Gap
Top Ring
Std: .0079-.0138I (.20-.36 mm)
Limit: .039I (1.0 mm)
Second Ring
Std: .0079-.0138I (.20-.36 mm)
Limit: .039I (1.0 mm)
Oil Ring
Std: .0079-.0276I (.20-.70 mm)
Limit: .059I (1.5 mm)
2. Measure installed gap with a feeler gauge at both
the top and bottom of the cylinder. NOTE: A
difference in end gap indicates cylinder taper.
The cylinder should be measured for excessive
taper and out of round.
3. If the bottom installed gap measurement exceeds
the service limit, replace the rings. If ring gap is
below specified limit, file ring ends until gap is
within specified range.
NOTE: Always check piston ring installed gap after
re-boring a cylinder or when installing new rings. A
re-bored cylinder should always be scrubbed
thoroughly with hot soapy water, rinsed, and dried
completely. Wipe cylinder bore with an oil rag
immediately to remove residue and prevent rust.
CRANKCASE DISASSEMBLY
NOTE: The recoil starter, starter motor, starter drive,
flywheel, stator, cam chain and sprockets can be
serviced with the engine in the frame.
Feeler Gauge
25-50mm
STARTER DRIVE
REMOVAL/INSPECTION
1. Remove recoil housing bolts and remove
housing.
2. Remove starter drive assembly. Note the thrust
washer located at the rear of the drive
mechanism.
3. Inspect the thrust washer for wear or damage and
replace if necessary.
Std. Bushing ID:
.4735"-.4740" (11.11-12.04 mm)
Std. Shaft OD:
.470"-.472" (11.93-11.99 mm)
Starter Drive Bushing Clearance:
Std: .0015"-.004" (.038-.102 mm)
Service Limit:
.008" (.203 mm)
4. Measure the OD of the starter drive shaft on both
ends and record.
A
3.31