Polaris PREDATOR 2003 Service Manual page 67

ENGINE
PISTON RING INSTALLED
GAP
1. Place each piston ring inside cylinder using piston
to push ring squarely into place.
Cylinder
Piston Ring
Piston Ring Installed Gap
Top Ring
Std: .008-.012I (.20-.30 mm)
Limit: .027I (.7 mm)
Second Ring
Std: .014-.019I (.35-.50 mm)
Limit: .031I (.8 mm)
Oil Ring
Std: .004-.019I (.10-.50 mm)
Limit: .039I (1.0 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 the gap is
within the 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 oil immediately to
prevent rust.
3.24
Feeler Gauge
25-50mm
CRANKCASE DISASSEMBLY
AND INSPECTION
NOTE: The starter motor, starter drive gears,
flywheel, stator, cam chain and sprockets can be
serviced with the engine in the frame.
NOTE: Crankcase and transmission components
cannot be serviced in the frame. Upper engine
components, with the exception of the starter and
stator removal, must be disassembled prior to
performing these procedures.
STARTER DRIVE GEARS REMOVAL
AND INSPECTION
1. Remove the starter.
2. Remove the 11 screws holding the stator cover
assembly.
3. Inspect the drive gears and shafts for wear or
damage and replace if necessary.
4. Measure the OD of the starter drive shafts on both
ends and record. Measure in two directions 90
apart to determine if components are out of round.
Replace if components are worn or damaged.