Piston Installation - Polaris Sportsman 400 Service Manual

PISTON INSTALLATION

1. Clean the gasket surfaces on the cylinder and
crankcase. Remove all traces of old gasket material.
2. Make sure the cylinder mounting bolt holes are clean
and free of debris.
3. Install a new circlip on one side of the piston with the
end gap facing up or down, and tang outward.
CAUTION: Circlips become deformed during the removal
process. Do not re-use old circlips. Do not compress the
new clip more than necessary upon installation to prevent
loss of radial tension. Severe engine damage may result
if circlips are re-used or deformed during installation.
4. Apply clean engine oil to the piston rings, ring lands,
piston pin bore, piston pin, and piston skirt. Lubricate
the connecting rod (both ends), balancer drive gear,
and crankshaft main bearing area.
5. Install the piston on the connecting rod with the arrow
or : mark facing the magneto (RH) end of the
crankshaft. The piston pin should be a push fit in the
piston.
6. Install the other circlip with the gap facing up or down
and tang outward. (See Caution with step 3 above).
Push the piston pin in both directions to make sure the
clips are properly seated in the groove.
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ENGINE
Tang Outward
:
or
Mag
3.65