Polaris Ranger 500 2x4 2007, Service Manual

Page: 69 / 345

3.10
ENGINE
Engine Installation Notes
After the engine is installed in the frame, review this checklist
and perform all steps that apply:
General Items
1. Repeat steps in reverse order in the “Engine Removal”
section above to reinstall the engine.
2. Install previously removed components using new gaskets,
seals, and fasteners where applicable.
3. Perform regular checks on fluid levels, controls, and all
important areas on the vehicle as outlined in the daily pre-
ride inspection checklist (refer to Chapter 2 or the Owner’s
Safety and Maintenance Manual).
PVT System
1. Adjust center distance of drive and driven clutch (Chapter
6).
2. Adjust clutch offset, alignment, and belt deflection
(Chapter 6).
3. Clean clutch sheaves thoroughly and inspect inlet and
outlet ducts for proper routing and sealing (Chapter 6).
Transmission
1. Inspect transmission operation and adjust linkage if
necessary. Refer to Chapter 2 and Chapter 8.
Exhaust
1. Replace exhaust gaskets. Seal connections with high temp
silicone sealant.
2. Check to be sure all springs are in good condition.
Bleed Cooling System
1. Remove radiator cap and slowly add coolant to top of filler
neck.
2. Fill coolant reservoir tank to full mark.
3. Install radiator cap and squeeze coolant lines to force air out
of system.
4. Again remove radiator cap and slowly add coolant to top
of fill neck.
5. Start engine and observe coolant level in the radiator.
Allow air to purge and top off as necessary. Reinstall
radiator cap and bring engine to operating temp. Check
level in reservoir tank after engine is cool and add coolant
if necessary.
Engine Break In Period
4 Cycle Engine Break-In Period is defined as the first 10 hours
of engine operation or 2 full tanks of fuel.
1. Use only Polaris Premium 4 All Season synthetic oil.
Never substitute or mix oil brands. Serious engine damage
can result.
2. Use fuel with a minimum octane of 87 (R+M)/2 method.
3. Change break-in oil and filter at 25 hours.
Cylinder Hone Selection / Honing Procedure
Cylinders may be wet or dry honed depending upon the hone
manufacturer’s recommendations. Wet honing removes more
material faster and leaves a more distinct pattern in the bore.
NOTE: See next page for more information on
honing.
Honing to Oversize
CAUTION
Selecting a hone which will straighten as well as
remove material from the cylinder is very
important. Using a common spring loaded finger
type glaze breaker for honing is never advised.
Polaris recommends using a rigid hone or arbor
honing machine which also has the
capability of oversizing.
CAUTION
If cylinder wear or damage is excessive, it will be
necessary to oversize the cylinder using a new
oversized piston and rings. This may be
accomplished by either boring the cylinder and
then finish honing to the final bore size, or by
rough honing followed by finish honing.
CAUTION
For oversize honing always wet hone using
honing oil and a coarse roughing stone.
Measure the piston (see piston measurement)
and rough hone to the size of the piston. Always
leave .002 - .003" (.05 - .07 mm) for finish honing.
Refer to piston-to-cylinder clearance
specifications on Page 3.5 before honing.
Complete the sizing with fine grit stones to
provide the proper cross-hatch finish and
required piston clearance.