Installing Top-Side Components - Tracker Off-Road 500S Service Manual

2. If excessive scoring, seizure marks, or pitting is
found, the cylinder head assembly must be replaced.
NOTE: If the journals are worn, replace the cam-

shaft.
Inspecting Camshaft Spring/Drive Pin
1. Inspect the spring and unloader pin for damage.
CF061A
NOTE: With the weight extended, the unloader pin

should be flat-side out; with the weight retracted, the
unloader pin should be round-side out.
CF060A
2. If damaged, the camshaft must be replaced.
Installing Top-Side
Components
A. Piston
B. Cylinder
1. Lubricate the piston pin, connecting rod, and piston
pin bore with motor oil; then install the piston on the
connecting rod making sure there is a circlip on each
side.
56
FI626
NOTE: The piston should be installed so the IN

points toward the intake side.
2. Place the two alignment pins into position. Place a
new cylinder gasket into position; then place a piston
holder (or suitable substitute) beneath the piston skirt
and square the piston in respect to the crankcase.
FI713
3. Lubricate the inside wall of the cylinder; then using a
ring compressor or the fingers, compress the rings
and slide the cylinder over the piston. Route the cam
chain up through the cylinder cam chain housing;
then remove the piston holder and seat the cylinder
firmly on the crankcase.
CAUTION
The cylinder should slide on easily. Do not force the cyl-
inder or damage to the piston, rings, cylinder, or crank-
shaft assembly may occur.
FI710
4. Loosely install the two nuts securing the cylinder to
the right-side crankcase half.