Polaris PREDATOR 2003, Service Manual

Page: 79 / 193

ENGINE
3.36
4. Check to make sure the rings rotate freely in the
groove when compressed
Ring Profile
Top -- Chrome
Install with mark facing up
Second -- Cast
Ill. 1
5. Orientate the rings for installation by rotating until
the end--gaps are 120 degrees apart.
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.
Gap should face up or down
3. Install a new circlip on one side of the piston with
the end gap facing up or down .
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.
Stator Side
Identification Mark
5. Install the piston on the connecting rod with the
identification mark facing the stator (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. (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.
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