Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 102 / 289

GENERAL INFORMATION
3.44
TENSIONER BLADE
INSTALLATION
1. Install the tensioner blade and tighten the
mounting bolt to specified torque.
Tensioner Blade Mounting Bolt Torque:
6 ft. lbs. (8 Nm)
PISTON RING INSTALLATION
NOTE: Apply clean engine oil to all ring surfaces and
ring lands. Always check piston ring installed gap
before rings are installed on piston. See Page 3.30.
If the piston has been in service clean any
accumulated carbon from the ring grooves and oil
control ring holes.
1. Place the oil control ring expander in oil ring
groove with the end gap facing forward. The
expander has no up or down marking and can be
installed either way. The ends should butt
squarely together and must not overlap.
2. Install the oil ring top rail.
NOTE: The top rail has a locating tab to prevent
rotation. The tab must be positioned in the notch on
the side of the piston as shown (A).
A
3. Install the bottom rail with the gap at least 30
°
from the end of the expander on the side opposite
the top rail gap.(See ILL. 1).
4. Install the second ring with the “R” mark facing up.
Position the end gap toward the rear (intake) side
of the piston.
5. Install the top ring (chrome faced) with the “R”
mark facing up and the end gap facing forward
(toward the exhaust). (See ILL. 1).
6. Check to make sure the rings rotate freely in the
groove when
compressed.
Ring Profile
Top
Mark up
Mark up
Second
ILL. 1
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