Cylinder Removal; Cylinder Inspection; Piston Removal - Polaris RANGER ETX 2015 Owner's Manual

CYLINDER REMOVAL

1. Remove and discard the head gasket
2. Position the cam chain and guides vertically.
w
3. Tap cylinder lightly with a plastic hammer in the
reinforced areas only until loose.
4. Rock cylinder forward and backward and lift it from
the crankcase, supporting piston
rod.
5. Remove the cylinder from the engine.
6. Remove and discard cylinder base gasket

CYLINDER INSPECTION

1. Remove all gasket material from the cylinder sealing
surfaces.
2. Inspect the top of the cylinder for warpage using a
straight edge and feeler gauge.
Cylinder Warpage:
.002 in. / 0.05 mm
3. Inspect cylinder for wear, scratches, or damage.
9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual
© Copyright Polaris Industries Inc.
4. Inspect cylinder for taper and out of round with a
telescoping gauge or a dial bore gauge. Measure in
q
.
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).
r
and connecting
5. Record measurements taken in Step 4. If cylinder is
tapered, or out of round beyond .001, cylinder must
e
.
be re-bored oversize, or replaced.

PISTON REMOVAL

1. Note piston directional indicator "∆" positioned
toward the magneto 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.
Do not apply heat to the piston rings, they may lose
3. Remove top ring.
*Using a piston ring pliers: Carefully expand ring
and lift it off the piston.
ENGINE / COOLING SYSTEM
Cylinder Taper
.00078 in. / 0.020 mm
Cylinder Out of Round
.00078 in. / 0.020 mm
Standard Bore Size:
3.07 +/- 0.0003" (78.0 +/- 0.008 mm)
CAUTION
radial tension.
3
3.55