Polaris Ranger 500 2x4 2007, Service Manual

Page: 91 / 345

3.32
ENGINE
Piston / Rod Inspection
1. Measure piston pin bore.
2. Measure piston pin O.D. Replace piston and/or piston pin
if out of tolerance.
3. Measure connecting rod small end ID.
4. 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 at right.
2. Measure installed gap with a feeler gauge at both the top
and bottom of the cylinder.
Piston Pin Bore:
.9055 - .9057” (23.0 - 23.006 mm)
Piston Pin O.D.
.9053 - .9055” (22.994 - 23.0 mm)
Piston Pin Bore
Piston Pin Measurement Locations
Piston Ring-to-Groove Clearance
Top Ring Std: .0016-.0031" (.040-.080 mm)
Limit: .0059" (15 mm)
Second Ring Std: .0012-.0028" (.030-.070 mm)
Limit: .0059" (15 mm)
Piston Ring Installed Gap
Top Ring
Std: .0079-.0138" (.20-.36 mm)
Limit: .039" (1.0 mm)
Second Ring
Std: .0079-.0138" (.20-.36 mm)
Limit: .039" (1.0 mm)
Oil Ring
Std: .0079-.0276" (.20-.70 mm)
Limit: .059" (1.5 mm)
Piston
Ring
Feeler Gauge
Feeler Gauge
Piston ring
Cylinder
25-50 mm