2008 Polaris Sportsman 500 EFI/X2/Touring/500 H.O. Service Manual, Page 90Get this manual
ENGINE Piston Ring Installed Gap
1Place each piston ring inside cylinder using piston to push ring squarely into place as shown at rightFeeler Gauge
Cylinder 23Measure piston pin O.DReplace piston andor piston pin if out of toleranceMeasure connecting rod small end IDPiston Ring
Piston Ring 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) 2Measure installed gap with feeler gauge at both the top and bottom of the cylinderNOTE: difference in end gap indicates cylinder taperThe cylinder should be measured for excessive taper and out of round 3If 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 range