Piston Pin Bore Inspection; Cylinder Inspection - Polaris Sportsman XP 1000 S 2020 Service Manual

3. If the installed gap measurement exceeds the service
limit, replace the rings.
MEASUREMENT
Piston Ring Installed Gap
Top: 0.014" ± 0.008" (0.36 ± 0.20 mm)
Second: 0.014" ± 0.008" (0.36 ± 0.20 mm)
Oil Control Rails:
0.0196" ± 0.010" (0.50 ± 0.25 mm)
IMPORTANT
Always check piston ring installed gap when installing
new rings and/or a new cylinder.

PISTON PIN BORE INSPECTION

1. Measure piston pin bore.
MEASUREMENT
Piston Pin Bore:
0.7877 ± .0002" (20.007 ± .004 mm)
9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc.
ENGINE / COOLING SYSTEM

CYLINDER INSPECTION

1. Remove all gasket material from gasket surface.
2. Lay a straight edge across cylinders (upper
crankcase).
3. Use a thickness gauge to measure gap between
straightedge and gasket surface. Measure at outer
edges and center, repeating measurements with
straightedge laid diagonally.
MEASUREMENT
Cylinder Warp:
0.002" (0.05 mm) Max.
4. Inspect cylinder for wear, scratches, or damage.
IMPORTANT
DO NOT hone the cylinders or attempt to repair a
damaged cylinder by honing.
5. Inspect taper and out of round with a dial bore
gauge.
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