Piston Installation; Piston Ring Installation - Polaris Outlaw 500 Service Manual

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.
Top Side of Piston
Identification Mark
5. Install the piston on the connecting rod with the
identification mark facing the stator 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.

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. 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. Install
the bottom and top rails.
2. Install the second ring with the mark facing up.
3. Install the top ring with the mark facing up.
4. Check to make sure the rings rotate freely in the groove
when compressed.
Stator Side
5. Orientate the rings for installation by rotating until the end-
gaps are 120 degrees apart.
Ring Profile
Top - Chrome
Install with mark facing up
Second - Cast
ENGINE
3
3.31