Piston Removal; Piston-To-Cylinder Clearance - Polaris RANGER 500 2018 Service Manual

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:
3.8976 +/- 0.0003" (99.0 +/- 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.
4. Repeat procedure for second ring.
5. Remove oil control ring top rail first, then bottom rail.
9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual
© Copyright Polaris Industries Inc.
ENGINE / COOLING SYSTEM
6. Remove oil control ring expander.

PISTON-TO-CYLINDER CLEARANCE

1. Measure the outside diameter of the piston 12 mm
from the skirt and at a right angle to the direction of
q
the piston pin .
2. Subtract this measurement from the maximum
cylinder size measurement from cylinder inspection.
Piston to Cylinder Clearance:
.00177 - .002925" (.045 - .075 mm)
Piston O.D.:
3.8957 - 3.8968" (98.953 - 98.980 mm)
3
3.163