Polaris 2003 Pro X Service Manual page 61

Assembly, Cont.
17. Assemble engine mount straps to crankcase.
Engine Mount Strap Torque:
44-48 ft. lbs. (60-66 Nm)
18. Lubricate main bearing oil holes with Polaris
Premium 2 Cycle or Premium Gold engine oil and
rotate crankshaft to distribute oil evenly.
19. Install a new C-clip in both pistons (inside) with gap
facing down. Be sure clip is fully seated in groove.
20. Lubricate and install new connecting rod small end
bearing in rod.
21. Install piston with arrow facing exhaust (ring
locating pins should be facing intake). Warming the
piston may help to ease installation of pin.
22. Install remaining C-clip with gap down. Be sure both
clips are fully seated in the groove.
23. Install new base gasket. Be sure gasket surface is
clean and free of nicks, burrs, or scratches.
24. Lubricate and install piston rings on piston with mark
on end of ring facing upward.
25. Place piston support under skirt and lubricate
pistons and cylinders thoroughly.
26. Align ring end gaps with locating pins and compress
rings. Install cylinder carefully with a gentle front to
rear rocking motion.
loosely. Do not tighten them at this time. Repeat
Steps 22-25 for other cylinder.
CAUTION:
Do not twist or force cylinder during installation.
27. Install new cylinder head O-rings and install cylinder
head. Make sure O-rings are properly seated in
grooves. Apply a light film of grease to hold O-rings
in place if necessary.
Install cylinder base nuts
ENGINE
Up
Straight Edge
Piston Ring Cutaway
Keystone Piston Ring
2.29