Polaris 2004-2005 Sportsman 6x6, Service Manual

Page: 103 / 289

GENERAL INFORMATION
3.45
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.
Mag
or
:
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.
CYLINDER INSTALLATION
1. Place the dowel pins in the crankcase and install a
new cylinder base gasket.
A
2. Position the Piston Support Block ( PN 2870390 )
(A) beneath the piston skirt to support the piston
during cylinder installation.
3. Apply clean engine oil to the ring compressor
(Snap On
t
PN RCL30) 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.
4. Apply clean engine oil liberally to the cylinder bore
and tapered area of the sleeve. Install the
cylinder with a slight rocking motion until the rings
are captive in the sleeve.
5. Remove the ring compressor and support block.
6. Push the cylinder downward until fully seated on
the base gasket.
7. Apply a light film of oil to the threads and flange
surface of the cylinder mounting bolts.
8. Install all four bolts finger tight. Rotate the engine
and position the piston at BDC.
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.