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Cylinder / Piston Installation - Polaris RZR XP 1000 Service Manual

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Cylinder / Piston Installation

Pistons must be installed into the cylinders with the
connecting rods attached.
DO NOT attempt to service the cylinder or pistons
without disassembling the crankcase. Although you can
remove the cylinder and pistons without disassembly,
you will not be able to reassemble the engine because
of the unique cylinder skirt and crankcase design.
NOTE: If the pistons are being reused, reassemble
in the same cylinder bore and direction from which
they were removed (MAG / PTO).
New pistons are directional (intake vs. exhaust), but
can be placed in either cylinder.
1. Apply clean engine oil to each piston assembly,
cylinder bore and bottom tapered portion of each
cylinder sleeve.
2. Verify that all ring end gaps are correctly located on
each piston (see Chapter 3 –
Installation, page 3.64).
3. Note the piston orientation mark (arrow) located on
top of the piston. Arrow should point toward the
exhaust side.
NOTE: Orientation arrow is also located on the
bottom side of piston as an additional reference.
9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual
4. Carefully compress the piston rings with your fingers
5. Rotate the engine so the crankcase to cylinder
Piston Ring
6. Clean base gasket sealing surface on cylinder and
7. Reinstall dowel pins in crankcase if previously
8. Install a new cylinder base gasket.
9. Verify piston orientation (arrow pointing toward
© Copyright 2014 Polaris Industries Inc.
and install the piston / connecting rod assemblies
into the cylinder from the bottom side.
NOTE: Use a slight front to back rocking motion
until all rings are captive in cylinder and past the
cylinder sleeve opening
mounting surface is facing up.
crankcase to remove all oil and grease.
NOTE: Base gasket and surfaces must be DRY
and oil free. Use care upon assembly to keep oil
exhaust) one last time prior to installation.


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