Piston / Connecting Rod Assembly; Cylinder Installation - Polaris 2014 Sportsman 570 EF Service Manual

Piston / Connecting Rod Assembly

1. Lubricate connecting rod small end, piston pin bore
and piston pin with engine oil.
CAUTION
Do not re-use circlips. Circlips become deformed during
the removal process.
Do not compress the new clip more than necessary to
prevent loss of radial tension. Severe engine damage
may result if circlips are re-used or deformed during
installation.
2. Install a new circlip on one side of piston with gap at
the top (12:00 position) or bottom (6:00 position).
NOTE: Never re-use a piston pin circlip.
3. When installing the piston, be sure the piston
marking "EX" is positioned towards the exhaust side
of the engine.
4. Place piston (A) on connecting rod (B). Push piston
pin (C) through rod and piston until it seats against
the installed circlip.
NOTE: Do not tap on pin or cause any sideways
force to connecting rod. Warm piston crown with
a heat gun if pin cannot be installed by hand, or
use a piston pin installation tool.
9924871 R03 - 2014 Polaris Sportsman® 570 EFI Service Manual
DO NOT apply heat to piston rings or a loss of
5. Install the remaining circlip (D) with gap at the top
(12:00 position) or bottom (6:00 position). Push the
piston pin in both directions to make sure the clips
are properly seated in the groove.

Cylinder Installation

1. Clean base gasket sealing surface on cylinder and
crankcase to remove all oil, grease, or old sealant.
2. Install a new base gasket.
NOTE: Base gasket and surfaces must be DRY
and oil free. Use care upon assembly to keep oil
away.
3. Slide a commercially available Piston Support Block
under piston skirt as shown to support piston during
cylinder installation.
© Copyright 2013 Polaris Sales Inc.
ENGINE
CAUTION
radial tension could result.
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