Polaris Ranger 500 2x4 2007, Service Manual

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3.44
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.
3. Install a new circlip on one side of the piston with the end
gap facing up or down, and tang outward.
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.
Cylinder Installation
1. Place the dowel pins in the crankcase and install a new
cylinder base gasket.
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™
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.
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.
Tang Outward
Mag
A