Cylinder / Piston Installation - Polaris RZR XP 1000 2014 Service Manual

ENGINE / COOLING SYSTEM

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.
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
Installation, page 3.65).
3. Note the piston orientation mark (arrow) located on
top of the piston. Arrow should point toward the
exhaust side.
Orientation arrow is also located on the bottom side of
piston as an additional reference.
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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.
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.
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.
9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual
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