Cylinder / Piston Installation - Polaris RANGER XP 900 2013 Manual

4. Install the remaining circlip
(12:00 position) or bottom (6:00 position). Push the
piston pin in both directions to make sure the clips
are properly seated in the groove.

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.
NOTE
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
w
cylinder bore and bottom tapered portion of each
cylinder sleeve.
2. Verify that all ring end gaps
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.
NOTE
Orientation arrow is also located on the bottom side of
piston as an additional reference.
9924880 Rev 2- 1/10/2014 - 2013 / 2014 RANGER XP 900 - 2014 RANGER XP 900 / CREW 900 Service Manual
© Copyright Polaris Sales Inc.
t
with gap at the top 4. Carefully compress the piston rings with your fingers
5. Rotate the engine so the crankcase to cylinder
q
,
6. Clean base gasket sealing surface on cylinder and
e
are correctly located
7. Reinstall dowel pins in crankcase if previously
8. Install a new cylinder base gasket.
9. Verify piston orientation (arrow pointing toward
10. Carefully place the cylinder and pistons into the
and install the piston / connecting rod assemblies
into the cylinder from the bottom side.
NOTE
Use a slight front to back rocking motion until all rings
are captive in cylinder and past the cylinder sleeve
r
opening
mounting surface is facing up.
crankcase to remove all oil and grease.
NOTE
Base gasket and surfaces must be DRY and oil free.
Use care upon assembly to keep oil away.
removed.
exhaust) one last time prior to installation.
upper crankcase.
ENGINE
.
3
3.67