9850067 R01 - 2020-2021
GENERAL
/
GENERAL XP
Service Manual
© Copyright Polaris Inc.
3.41
5.
Remove the piston / connecting rod assemblies from
the cylinder.
NOTICE
If the pistons are to be reused, mark the pistons so they
are reassembled in the same cylinder bore and
direction from which they were removed (MAG / PTO).
PISTON DISASSEMBLY / INSPECTION
(1000)
NOTICE
New pistons are directional (intake vs. exhaust), but
can be placed in either cylinder.
1.
Note location of the piston circlip gap
q
at the top
(12:00 position) or bottom (6:00 position).
2.
Remove piston circlip and push piston pin out of
piston. If necessary, heat the crown of the piston
slightly with a heat gun if pin cannot be removed by
hand. Discard circlips.
IMPORTANT
DO NOT apply heat to piston rings or a loss of radial
tension could result.
3.
Measure piston pin bore I. D. in two directions (90°
apart). Replace piston and piston pin if out of
specification.
MEASUREMENT
Piston Pin Bore I.D.:
.7877 - .7881" (20.009 - 20.018 mm)
Service Limit:
.7893" (20.05 mm)
