600 Ho Carbureted Pistons / Crankshaft - Polaris IQ 2007 Service Manual

600 HO Carbureted Pistons / Crankshaft

PISTON PIN
C-CLIP
FLYWHEEL KEY
BEARING
MAG CRANKCASE SEAL
Piston Matrix
Engine Model
S3273-6044-PF6F
(Subs to 2203319)
S3274-6044-PF6F
S3466-6044-PU6F
S3467-6044-PU6F
Disassembly / Assembly Process
1. To remove the pistons, follow the process for removing the
cylinder head and cylinders from the engine.
2. To remove the crankshaft, follow the process for
disassembling the crankcase assembly.
3. With the piston out of the cylinder, remove one of the c-
clips and discard. Never re-use piston c-clips.
4. Push the piston pin out of the piston and upper rod bearings.
Inspect the pin for galling and abnormal wear. Inspect the
needle bearing by feel and replace as required.
5. New pistons are supplied with new rings and a piston pin.
It is recommended that new needle bearings be installed as
well.
PISTON RINGS
PISTON
Piston PN Piston ID
2202258
EK-2202b
2203319 EK-2202c
Engine and Cooling Systems
NEEDLE BEARINGS
6. When installing a new piston, insert one c-clip into the
piston making sure the open end is 180° opposite of the
groove opening.
7. Apply a liberal amount of Polaris two-stroke engine oil to
the needle bearings, piston pin and piston assembly.
8. Push the pin in to the piston, then through the needle
bearing. Install the remaining c-clip with the open end is
180° opposite of the groove opening.
NOTE: Always use new cylinder base gaskets.
9. Apply a liberal amount of Polaris two-stroke oil to the
cylinder wall. Align the piston ring gaps around the piston
locating pins. Compress the upper ring, then carefully slide
the cylinder down over the ring.
10. Compress the lower ring, then slide the cylinder down over
the ring.
PTO CRANKCASE SEAL
BEARINGS
5
5.19