Piston Removal; Cylinder Inspection - Polaris 2007 Sportsman 500 EF Service Manual

ENGINE

Piston Removal

1. Remove circlip. Note piston directional arrow pointing
toward the right (Mag) side of engine.
1. Remove piston circlip and push piston pin out of piston. If
necessary, heat the crown of the piston slightly with a
propane torch.
2. Remove top compression ring.
CAUTION
Do not apply heat to the piston rings. The ring may
lose radial tension
*Using a piston ring pliers: Carefully expand ring and lift it off
the piston.
CAUTION
Do not expand the ring more than necessary to
remove it from the piston or the ring may break
3.28
*By hand: Placing both thumbs as shown, spread the ring open
and push up on the opposite side. Do not scratch the ring lands.
3. Repeat procedure for second ring.
The oil control ring is a three piece design consisting of a top and
bottom steel rail and a center expander section. The top rail has
a locating tab on the end which fits into a notch (A) in the upper
oil ring land of the piston.
4. Remove the top rail first followed by the bottom rail.
5. Remove the expander.

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 Warp Limit:
.002" (.05 mm)
A