Polaris 2006 HAWKEYE 2x4, Repair Manual

Page: 66 / 217

3.28
ENGINE
6. Measure piston ring to groove clearance by placing
the ring in the ring land and measuring with a
thickness gauge. Replace piston and rings if ring-to-
groove clearance exceeds service limits.
PISTON RING INSTALLED GAP
1. Place each piston ring inside cylinder using piston to
push ring squarely into place as shown.
2. Measure the gap with a feeler gauge at both the top
and bottom of the cylinder.
NOTE: Measure at two points in the cylinder A
difference in end gap indicates cylinder taper. The
cylinder should be measured for excessive taper and out
of round.
3. If the installed gap measurement exceeds the limit,
replace the rings. If using new rings and the
measurement is too small, file the ring ends to achieve
the proper gap.
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 an oil rag immediately to remove residue and
prevent rust.
FLYWHEEL REMOVAL / INSPECTION
1. Remove the recoil housing, recoil hub, and flywheel
nut.
2. Install Flywheel Puller ( PN PA-47308 ) and remove
flywheel. CAUTION: Do not hammer or strike the tool
while attached to the crankshaft end .
Piston Ring Installed Gap
Top Ring
Std: .008- .012” (.2- .3 mm)
Limit: .032” (0.8 mm)
Second Ring
Std: .014- .020” (0.35- 0.50 mm)
Limit: .039” (1.0 mm)
Oil Ring
Std: .008- .028” (0.2- 0.7 mm)
Limit: .059” (1.5 mm)
Feeler Gauge
Ring
Piston
Piston Ring
Cylinder
Feeler Gauge
25-50 mm
Piston ring installed end gap
CAUTION
The crankshaft end contains an oil passage plunge
joint (A) as shown below. The plunger must be able
to move in and out freely. Avoid damage to the
crankshaft end or plunge joint and spring, which
can cause loss of oil pressure, resulting in severe
engine damage.