Cylinder Head Installation; Cylinder Installation - Polaris Trail Boss 330 2003 Service Manual

ENGINE
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) and
crankshaft main bearing area.
5. Install the piston on the connecting rod with
the pin casting notch facing the rear of engine
(starter side). The piston pin should be a
push fit in the piston.
6. Install the other circlip with the gap facing up or
down. (See Caution with Step 3 above). Push the
piston pin in both directions to make sure the clips
are properly seated in the groove.
7. Place the dowel pins in the crankcase and install a
new cylinder base gasket.
8. Lubricate the piston and rings with assembly lube
and install a sleeve--type ring compressor on the
piston assembly. Verify that the ring gaps are 120
degrees apart from each other before installation.

CYLINDER INSTALLATION

1. Position the Piston Support Block (PN 2870390)
(A) beneath the piston skirt to support the piston
during cylinder installation.
A
3.36
2. Apply clean engine oil liberally to the cylinder bore
and tapered area of the sleeve.
cylinder with a slight rocking motion until the rings
are captive in the sleeve.
3. Remove the ring compressor and support block.
4. Push the cylinder downward until fully seated on
the base gasket.
NOTE: If cam chain is installed, hold it up while
rotating the engine to avoid damage to the chain, drive
sprocket teeth, or tensioner blade.
5. Install the two 6 mm bolts, but do not tighten.
CYLINDER HEAD
INSTALLATION
Clean the gasket surfaces on the cylinder head and
cylinder. Remove all traces of old gasket material.
1. Install the cam chain tensioner guide. Be sure
bottom end of guide is located properly in
crankcase.
2. Install the two dowel pins and a new cylinder head
gasket.
3. Place the cylinder head on the cylinder. Apply a
film of engine oil to the cylinder head bolt threads
and washers, and hand tighten the bolts.
Install the