2003 Polaris Sportsman 600, 2002-2003 Polaris Sportsman 700 Service Manual, Page 85Get this manual
Piston Ring Installed Gap 600 Piston Ring Top Ring: 0.01181 0.00393 (0.30 0.10 mm) Second Ring Limit: 0.01476 0.00492 (0.375 0.125 mm) Oil Ring Limit: 0.00984 .00393 (0.25 0.10 mm) 700 Feeler Gauge Top Ring Limit: 0.01083 0.00295 (0.275 0.075 mm) Second Ring Limit: 0.0177 0.00394 (0.45 0.10 mm) Oil Ring Limit: 0.0177 .00984 (0.45 0.25 mm) NOTE: Ring should be installed with the mark on the ring facing upward2Measure installed gap with feeler gauge (C) at both the top and bottom of the cylinderREMINDER: difference in end gap indicates cylinder taperThe cylinder should be measured for excessive taper and out of round3If the bottom installed gap measurement exceeds the service limit, replace the ringsIf ring gap is smaller than the specified limit, file ring ends until gap is within specified rangeNOTE: Always check piston ring installed gap after re-boring cylinder or when installing new ringsA re-bored cylinder should always be scrubbed thoroughly with hot soapy water, rinsed, and dried completelyWipe cylinder bore with oil immediately to remove residue and prevent rust