Cylinder / Piston Installation - Polaris GENERAL 2016 Service Manual

CYLINDER / PISTON INSTALLATION

CAUTION
Pistons must be installed into 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.
NOTICE
If the pistons are being reused, reassemble in the same
cylinder bore and direction from which they were
removed (MAG / PTO).
New pistons are directional (intake vs. exhaust), but
can be placed in either cylinder.
1. Apply clean engine oil to each piston assembly,
cylinder bore and bottom tapered portion of each
cylinder sleeve.
2. Verify that all ring end gaps are correctly located on
each piston (see Chapter 3 – Piston Ring
Installationpage 3.62).
3. Note the piston orientation mark (arrow) located on
top of the piston. Arrow should point toward the
exhaust side.
NOTICE
Orientation arrow is also located on the bottom side of
piston as an additional reference.
9929375 R02 - 2016-2019 GENERAL / GENERAL 4 Service Manual
© Copyright Polaris Industries Inc.
ENGINE / COOLING SYSTEM
4. Carefully compress the piston rings with your fingers
and install the piston assemblies into the cylinder
from the bottom side. Use piston ring compressor
pliers (PV-43570-1) to aid in assembly, if necessary.
NOTICE
Use a slight front to back rocking motion until all rings
are captive in cylinder and past the cylinder sleeve
opening
5. Rotate the engine so the crankcase to cylinder
mounting surface is facing up.
6. Clean base gasket sealing surface on cylinder and
crankcase to remove all oil and grease.
NOTICE
Base gasket and surfaces must be DRY and oil free.
Use care upon assembly to keep oil away.
7. Reinstall dowel pins in crankcase if removed.
8. Install a new cylinder base gasket.
9. Verify piston orientation (arrow pointing toward
exhaust) one last time prior to installation.
3
q
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3.65