Polaris 2000 120 XCR Service Manual page 63

ENGINE / CARBURETOR / CLUTCH
6. Install the oil ring first (4), then second ring (5), then top
ring (6). Spread the ring only far enough to slip over the
piston and into the correct groove (7). Use care not to distort
the ring. Install the second ring with the punched mark "R"
(8) beside the gap on the tip side.
R
7. When installing the piston on the connecting rod, place the
valve recess (10) of the piston crown as shown in the
illustration to the "MAG" side of the connecting rod. Apply
oil to the small end of the connecting rod, piston and piston
pin before installation. Be sure clips on both ends of the
piston pin are secure and seated in grooves.
4.24
6
5
4
7
9
10
8. Install connecting rod cap.
9. Torque Connecting Rod to specification.
Connecting Rod Cap Bolt 6.5-8.3 ft.lb (8.8-11.2Nm)
10. Lubricate the oil seal and bearing surfaces. Add a light film
of oil to the main bearing cover face to hold the gasket in
place. Place spacers chosen on crankshaft and camshaft.
Carefully install cover, guiding oil seal over shaft to avoid
seal damage and to prevent spring from dislodging when
installing the main bearing cover. Tap the cover into place
with a soft face hammer. Tighten crankcase bolts to
specification.
Crankcase Bolts 6-7 ft.lb. (8-9.5Nm)
11. Clean carbon and gum deposits from the valves, seats,
ports, and guides. Inspect the valves, valve seats, and valve
guides
12. Replace valves that are badly burned, pitted, or warped.
13. When installing valves in cylinder head, oil valve stems and
insert them into the valve guide. Then place cylinder head
on a flat table, install the valve springs, spring retainers, and
valve collets.
14. Valve guides should be replaced when the valve stem
clearance exceeds specifications. Draw the valve guides
out and press the new guides in. See "CLEARANCE
DATA & LIMITS" on page 4.5. After replacing the valves
and guides, lap valves in place until a uniform ring shows
around the face of the valve. Clean valves and wash
cylinder head thoroughly.
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