Piston Installation; Cylinder Installation - Polaris 2007 Sportsman 500 EF Service Manual

ENGINE

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.
Tang Outward
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.
3.44
Mag
or :

Cylinder Installation

7. Place the dowel pins in the crankcase and install a new
cylinder base gasket.
8. Position the Piston Support Block (PN 2870390) (A)
beneath the piston skirt to support the piston during
cylinder installation.
A
9. Apply clean engine oil to a ring compressor and install the
compressor following manufacturers instructions.
CAUTION
Make sure the oil control ring upper rail tab is
positioned properly in the notch of the piston. Verify
all ring end gaps are correctly located.