Piston Installation; Tensioner Blade Installation; Cylinder Installation - Polaris PREDATOR 50 2009 Manual

Piston Installation

CAUTION
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.
1. Install a new circlip on one side of the piston with the end
gap facing up or down.
2. Apply clean engine oil to the piston rings, ring lands, piston
pin bore, piston pin, and piston skirt. Lubricate the
connecting rod (both ends) and crankshaft main bearing
area.
3. IMPORTANT: Install the piston on the connecting rod
with the 'IN" casting mark facing the intake side of engine.
The piston pin should be a push fit into the piston.
4. Install the other circlip. Push piston pin in both directions
to make sure clips are properly seated in the grooves.
5. Place dowel pins in crankcase and install a new cylinder
base gasket.
6. Lubricate piston and rings with engine oil. Verify that the
°
ring gaps are 120 apart from each other before installation.

Tensioner Blade Installation

1. Install tensioner blade and tighten mounting bolt to
specified torque (arrow).
Tensioner Blade Mounting Bolt Torque:

Cylinder Installation

NOTE: Clean gasket surfaces on crankcase and
cylinder thoroughly.
"IN"
1. Install the dowel pin(s). Install a new base gasket
2. Apply engine oil liberally to cylinder bore and tapered area
at bottom of cylinder. Place cylinder onto cylinder studs.
3. Guide cam chain through cylinder and secure with wire.
4. Install a ring compressor or compress rings with fingers and
guide piston into taper at bottom of cylinder.
5. When rings are past the tapered portion of cylinder, install
cylinder until seated against base gasket.
ENGINE / TRANSMISSION
104 in. lbs. (11.8 Nm)
3
3.29