Cylinder Block Installation; Spec Ial Tools - Polaris 1999 Sportsman 400 Service Manual

122
12, Chec k the thread ed fitting for the oi l filter (Fi g-
ure 109) for wear or damage , Replace the li lting if
necessary.
Installation
To make installation of the cylin der block ove r
the piston saferand easier. two special tools are
very
helpful. Cylinder block installation can be accom-
plished without these tools. but is more difficult and
also increases the chance of dama ge to hot h the cyl-
inder wall surfaces and to the piston rings and skirt,
The spec ial tools arc a piston holding fi xture (A.
Figu re 110) and a ring compressor (B. Figure (10 )
and arc avai lable through Polaris dea lerships or af-
termarket parts suppliers,
I , Clean the crankcase matin g surface of all gaske t
residue (Fi gu re II I) ,
2. Check that the top and bottom o f the cylinder
hlock surfaces are clean of all gas ket residue ,
3, If remo ved. install the cy linder block locating
dowels (A. Figure 112),
4 , Install a new cylinder block base gasket (B. Fig-
ure 112), Make sure all holes align,
5. If removed, install the piston as described in this
chapter.
6, Insert the piston hold ing fixtu re (F igure 113)
under the piston,
7. Check that both piston pin clips are installed and
seated correctly.
8, Lubri cate the cylinder wall. piston and rings lib-
erally wi th clean engine oil prior to installation.
9. Make sure the oil ring top rail is correctly posi-
tioned in the notch as shown in Figure 114. The
gaps in the remaining rings should be spaced evenly
around the piston.
C HA PTER FOUR