9850067 R01 - 2020-2021
GENERAL
/
GENERAL XP
Service Manual
© Copyright Polaris Inc.
3.43
PISTON RING INSTALLED GAP (1000)
1.
Place each piston ring
q
inside the cylinder
w
. Use
the piston to push the ring squarely into cylinder, as
shown below.
2.
Measure installed gap with a feeler gauge
e
at both
the top and bottom of the cylinder.
NOTICE
A difference between top and bottom end gap
measurements is a general indication of cylinder taper
(wear). The cylinder should be measured for taper and
out of round.
3.
If the installed gap measurement exceeds the
service limit, replace the rings.
MEASUREMENT
Piston Ring Installed Gap:
Top Ring:
.010 - .014" (0.25 - 0.35 mm)
Service Limit:
1.6118 - 1.6122" (40.942 - 40.950 mm)
Second Ring:
1.6118 - 1.6122" (40.942 - 40.950 mm)
Service Limit:
.028" (0.70 mm)
Oil Control Rails:
.008 - .028" (0.20 - 0.70 mm)
Service Limit:
.0354" (0.9 mm)
NOTICE
Always check piston ring installed gap when installing
new rings and/or a new cylinder.
PISTON-TO-CYLINDER CLEARANCE
Measure piston outside diameter at a point 10 mm
q
up
from the bottom of the piston, at a right angle to piston
pin bore.
Subtract measurement from maximum measurement
obtained in Step 4 of Cylinder Inspection page
3.39“Cylinder Inspection” procedure.
MEASUREMENT
Piston O.D. (Standard):
3.6597 ± .0003" (92.959 ± 0.008 mm)
Piston to Cylinder Clearance:
.0009 - .0019" (0.025 - 0.050 mm)
