Piston Removal - Polaris RANGER 500 2018 Service Manual

ENGINE / COOLING SYSTEM
2. Inspect the top of the cylinder for warpage using a
straight edge and feeler gauge.
Cylinder Warpage:
.00098" (.025 mm)
3. Inspect cylinder for wear, scratches, or damage.
4. Inspect cylinder for taper and out of round with a
telescoping gauge or a dial bore gauge. Measure in
two different directions, front to back and side to side,
on three different levels (1/2" down from top, in the
middle, and 1/2" up from bottom).
3.74
5. Record measurements taken in Step 4. If cylinder is
tapered, or out of round beyond .001, cylinder must
be re-bored oversize, or replaced.
Cylinder Taper Limit:
.001" Max. (0.025 mm)
Cylinder Out of Round Limit:
.001" Max. (.025 mm)
Standard Bore Size:
3.6614 +/- 0.0003" (93.0 +/- 0.008 mm)

PISTON REMOVAL

1. Note piston directional indicator "EX" positioned
toward the exhaust side of engine.
2. Remove piston circlip and push piston pin out of
piston. If necessary, heat the crown of the piston
slightly with a heat gun.
CAUTION
Do not apply heat to the piston rings, they may lose
radial tension.
3. Remove top ring.
*Using a piston ring pliers: Carefully expand ring and
lift it off the piston.
CAUTION
Do not expand the ring more than the amount
necessary to remove it from the piston.
*By hand: Using both thumbs, spread the ring open
and push up on the opposite side.
9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual
NOTE
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