Piston / Connecting Rod Assembly; Piston / Connecting Rod Installation - Polaris Sportsman XP 1000 S 2020 Service Manual

ENGINE / COOLING SYSTEM
PISTON / CONNECTING ROD
ASSEMBLY
1. Lubricate connecting rod small end, piston pin bore,
and piston pin with engine oil.
IMPORTANT
Do not re-use circlips. Circlips become deformed during
the removal process.
Do not compress the new clip more than necessary to
prevent loss of radial tension. Severe engine damage
may result if circlips are re-used or deformed during
installation.
2. Install a new circlip on one side of piston with gap UP
(at the 12:00) or DOWN (at the 6:00) position.
NOTICE
If re-installing connecting rods, orient marks on rod
caps the same as when removed. Be aware of this
direction when installing pistons to rods. If new
connecting rods are being installed, they can be
installed either way (there is no piston pin offset)
however it is recommended they be installed with
marks on both rods facing the same direction.
3. Place piston on connecting rod. Replacement
pistons can be installed in either orientation as they
are symmetrical.
4. Push piston pin through rod and piston until it seats
against the installed circlip.
IMPORTANT
Do not tap on pin or cause any sideways force to
connecting rod. Warm piston crown with a heat gun if
pin cannot be installed by hand or use a piston pin
installation tool. DO NOT apply heat directly to piston
rings or a loss of radial tension could result.
3.66
5. Install the remaining circlip with gap at the top or
bottom. Push the piston pin in both directions to
make sure the clips are properly seated in the
groove.
IMPORTANT
Never re-use a piston circlip.
6. Check to be sure rings rotate freely in the grooves.
PISTON / CONNECTING ROD
INSTALLATION
1. Apply clean engine oil to piston assembly and
cylinder walls of upper crankcase.
2. Be sure ring end gaps are positioned at least 120
degrees apart. Oil ring rails at least 60 degrees
apart. See "Piston Ring Installation".
3. Apply engine oil to ring compressor band and install
band (A) over piston rings.
IMPORTANT
Be sure compressor band end gap does not align with
any ring end gap when compressing the rings.
4. Fully compress piston rings using compressor pliers
(B) on band.
Piston Ring Compressor Band, 87 mm:
PV-43570-3
Piston Ring Compressor Pliers:
PV-43570-1
5. Apply tape to the sides of connecting rods to protect
cylinder from damage.
6. Align piston with bore and push into cylinder until all
rings are captive. Remove ring compressor.
9931493 R03 - 2020-2021 Sportsman XP 1000 S Service Manual
© Copyright Polaris Inc.