Cylinder / Piston Removal; Piston Disassembly / Inspection (1000) - Polaris GENERAL 2016 Service Manual

CYLINDER / PISTON REMOVAL

CAUTION
Pistons must be removed from 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.
1. Perform ENGINE DISASSEMBLY / INSPECTION -
TOP ENDpage 3.35 and ENGINE DISASSEMBLY /
INSPECTION - BOTTOM ENDpage 3.45 and the
procedures.
2. Rotate the engine so the cylinder is facing up.
3. Remove the Cylinder Holding & Camshaft Timing
q
Plate (PU-50563) from the cylinder.
4. Carefully lift the cylinder and pistons from the upper
crankcase.
9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual
© Copyright Polaris Industries Inc.
ENGINE / COOLING SYSTEM
5. Remove the piston / connecting rod assemblies from
the cylinder.
NOTICE
If the pistons are to be reused, mark the pistons so they
are reassembled in the same cylinder bore and
direction from which they were removed (MAG / PTO).
PISTON DISASSEMBLY / INSPECTION
(1000)
NOTICE
New pistons are directional (intake vs. exhaust), but
can be placed in either cylinder.
1. Note location of the piston circlip gap
(12:00 position) or bottom (6:00 position).
3
q
at the top
3.55