Piston Ring Installed Gap; Honing To Oversize - Polaris RANGER 500 2018 Service Manual

ENGINE / COOLING SYSTEM
3. Measure connecting rod small end ID. Inspect
bearing surface for damage.
Piston Pin Degree of Fit:
Pin should be a push-fit by hand with piston at room
temperature or warmed slightly
Connecting Rod Small End ID:
Std.: 0.8665 - 0.8670" (22.010 - 22.023 mm)
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-to-Groove Clearance
Top Ring:
Std.: 0.0011 - 0.0037" (0.030 - 0.095 mm)
Service Limit: 0.0042" (0.108 mm)
Second Ring:
Std.: 0.0007 - 0.0029" (.020 - 0.076 mm)
Service Limit: 0.0035" (0.89 mm)
3.76

PISTON RING INSTALLED GAP

1. Place each piston ring inside cylinder. Use a piston to
push the ring squarely into place 1" (25.4 mm) down
from the cylinder head gasket surface.
2. Measure installed gap with a feeler gauge at location
q
.
Piston Ring Installed Gap
Top Ring:
Std: 0.0059 - 0.0122" (0.15 - 0.31 mm)
Limit: 0.0137" (0.35 mm)
Second Ring:
Std: 0.0094 - 0.0196" (0.24 - 0.50 mm)
Limit: 0.022" (0.56 mm)
Oil Ring Rails:
Std: 0.0098" - 0.0401" (0.25 - 1.02 mm)
Limit: 0.0480" (1.22 mm)
Always check piston ring installed gap after re-boring a
cylinder or when installing new rings.

HONING TO OVERSIZE

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
9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual
NOTE
honing.
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