Polaris Outlaw 500, Service Manual

Page: 91 / 202

3.44
ENGINE
If cylinder wear or damage is excessive, it will be necessary to
replace the cylinder. Hone only enough to deglaze the outer
layer of the cylinder bore.
Piston Ring Installed Gap
1. Place each piston ring inside cylinder using piston to push
ring squarely into place.
2. Measure installed gap with a feeler gauge at both the top
and bottom of the cylinder.
NOTE: A difference in end gap indicates cylinder
taper. The cylinder should be measured for
excessive taper and out of round.
3. If the bottom installed gap measurement exceeds the
service limit, replace the rings. If ring gap is below
specified limit, file ring ends until the gap is within the
specified range.
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 oil immediately
to prevent rust.
WATER PUMP SERVICE
Oil Seal / Mechanical Seal Removal
(Engine Disassembled)
NOTE: The water pump mechanical seal can be
removed without removing the engine. Refer to
Water Pump Mechanical Seal Installation.
Replace the water pump mechanical seal whenever the
crankcase is disassembled.
1. Remove the pump shaft bearings from the PTO (right
hand) side crankcase.
2. Drive the water pump mechanical seal out of the crankcase
from inside to outside.
NOTE: The new mechanical seal must be installed
using special tools. See Mechanical Seal Installation.
Water Pump Mechanical Seal Installation
1. Clean the seal cavity to remove all traces of old sealer.
2. Place a new mechanical seal in the seal drive collar, and
install on the pump shaft.
3. Screw the guide onto the end of the pump shaft.
4. Install the washer and nut and tighten to draw seal into place
until fully seated.
5. Remove the guide adaptor using the additional nut as a jam
nut if necessary.
Piston Ring Installed Gap
Top Ring
Std: .008- .012
″
(.20- .30 mm)
Limit: .027” (.7 mm)
Second Ring
Std: .014- .019
″
(.35- .50 mm)
Limit: .031” (.8 mm)
Oil Ring
Std: .004- .019
″
(.10- .50 mm)
Limit: .039” (1.0 mm)
Piston Ring
Cylinder
Feeler Gauge
25-50 mm
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