Polaris Ranger 500 2x4 2007, Service Manual

Page: 102 / 345

3.43
ENGINE
3
One Way Valve Installation
Install the one way valve plunger, spring, and plug using a new
sealing washer.
Cam Chain Drive Sprocket Installation
1. Install the Woodruff key, drive sprocket (B), and slotted
nut (A). Tighten the nut to the specified torque.
Tensioner Blade Installation
1. Install the tensioner blade and tighten the mounting bolt to
specified torque.
Piston Ring Installation
NOTE: Apply clean engine oil to all ring surfaces
and ring lands. Always check piston ring installed
gap before rings are installed on piston. See Page
3.32. If the piston has been in service clean any
accumulated carbon from the ring grooves and oil
control ring holes.
1. Place the oil control ring expander in oil ring groove with
the end gap facing forward. The expander has no up or
down marking and can be installed either way. The ends
should butt squarely together and must not overlap.
2. Install the oil ring top rail.
NOTE: The top rail has a locating tab to prevent
rotation. The tab must be positioned in the notch on
the side of the piston as shown (C).
3. Install the bottom rail with the gap at least 30
o
from the end
of the expander on the side opposite the top rail gap.
4. Install the second ring with the “R” mark facing up.
Position the end gap toward the rear (intake) side of the
piston.
5. Install the top ring (chrome faced) with the “R” mark facing
up and the end gap facing forward (toward the exhaust).
6. Check to make sure the rings rotate freely in the groove
when compressed.
One Way Valve Plug Torque:
16 ft. lbs. (22 Nm)
Slotted Nut Torque:
35-51 ft. lbs. (4.71-6.86 kg-m)
Tensioner Blade Mounting Bolt Torque:
6 ft. lbs. (8 Nm)
A
B
Tighten
C
Mark-up
Top
Second
Ring Profile
Mark-up