Starter Bendix Removal/Inspection; Piston Ring Installed Gap - Polaris SPORTSMAN 600 2003 Service Manual

ENGINE ENGINE
Piston
Piston Ring-to-Ring Groove Clearance
Top Ring Limit: 0.0019"
(0.0475
Second Ring Limit : 0.0017"
(0.0425

PISTON RING INSTALLED GAP

1. Place each piston ring (A) inside cylinder (B)
using piston to push ring squarely into place as
shown. (See next page)
B
A
Ring
Feeler Gauge
0.00069"
0.0175 mm)
0.00049"
.0125 mm)
C
25-50mm
Piston Ring Installed Gap
600
Top Ring: 0.01181"
(0.30
Second Ring Limit: 0.01476"
(0.375
Oil Ring Limit: 0.00984"
(0.25
Top Ring Limit: 0.01083"
(0.275 0.075 mm)
Second Ring Limit: 0.0177"
(0.45 0.10 mm)
Oil Ring Limit: 0.0177"
(0.45 0.25 mm)
NOTE: Ring should be installed with the mark on the
ring facing upward.
2. Measure installed gap with a feeler gauge (C) at
both the top and bottom of the cylinder.
REMINDER: 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
smaller than the 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 oil immediately to
remove residue and prevent rust.
STARTER DRIVE/BENDIX
REMOVAL/INSPECTION
1. Remove stator housing bolts and remove
housing.
2. Remove the flywheel nut and washer. Install
Flywheel Puller (PN 2871043) and remove
flywheel. CAUTION: Do not thread the puller
bolts into the flywheel more than 1/4 or stator
coils may be damaged.
3. Remove starter bendix assembly (A). Note the
thrust washers located on both sides of the
bendix.
0.00393"
0.10 mm)
0.00492"
0.125 mm)
.00393"
0.10 mm)
700
0.00295"
0.00394"
.00984"
3.33