Piston Removal - Polaris Sportsman 800 EFI 4x4 2012 Service Manual

ENGINE

Piston Removal

1. Remove circlip (A). Mark the piston with a white pen
to ensure proper orientation (if reused) during
assembly.
IMPORTANT: If the pistons are to be reused,
reassemble the pistons in the same cylinder and
direction from which they were removed.
New pistons are non-directional and can be
placed in either cylinder.
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 scratch the ring lands.
3.36
4. Repeat procedure for second ring.
5. Remove the oil control ring.
The oil control ring is a three piece design consisting
of a top and bottom steel rail and a center expander
section. The top rail has a locating tab on the end
which fits into a notch (B) in the upper oil ring land of
the piston.
To Remove:
A) Remove the top rail first followed by the bottom
rail.
B) Remove the expander.
9924864 - 2012-2014 SPORTSMAN 800 / 6X6
© Copyright 2013 Polaris Sales Inc.