2005-2007 Polaris Ranger 500 service manual, Page 91Get this manual
ENGINE NOTE: 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 below specified limit, file ring ends until gap is within specified rangeA
NOTE: 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 an oiled rag immediately to remove residue and prevent rust
StdBushing ID: .4735"-.4740" (11.11-12.04 mm) StdShaft OD: .470"-.472" (11.93-11.99 mm) Starter Drive Bushing Clearance: Std: .0015"-.004" (.038-.102 mm) Service Limit: .008" (.203 mm) 6Inspect gear teeth on starter driveReplace starter drive if gear teeth are cracked, worn, or broken
Crankcase Disassembly
NOTE: The recoil starter, starter motor, starter drive, flywheel, stator, cam chain and sprockets can be serviced with the engine in the frame