Piston Support Block - Polaris 2005 SPORTSMAN 500 Servise Manual

ENGINE
3. Loosen hose clamps and remove coolant inlet
hose.
4. Remove the two 6 mm cylinder base bolts.
5. Loosen each of the four large cylinder base bolts
1/4 turn at a time in a criss-cross pattern until
loose and remove bolts.
NOTE: The bolts are inside the water jacket.
3.28
6. Tap cylinder lightly with a plastic hammer in the
reinforced areas only until loose.
7. Rock cylinder forward and backward and lift it
from the crankcase, supporting piston and
connecting rod. Support piston with Piston
Support Block (PN 2870390).
8. Remove dowel pins from crankcase.
PISTON REMOVAL
1. Remove circlip. Note piston directional arrow
pointing toward the right (Mag) side of engine.
2. Remove piston circlip and push piston pin out of
piston. If necessary, heat the crown of the piston
slightly with a propane torch. CAUTION: Do not
apply heat to the piston rings. The ring may lose
radial tension.
3. Remove top compression ring.
*Using a piston ring pliers: Carefully expand ring
and lift it off the piston. CAUTION: Do not expand the
ring more than the amount necessary to remove it
from the piston, or the ring may break.
*By hand: Placing both thumbs as shown, spread the
ring open and push up on the opposite side. Do not