Cylinder And Piston Removal; Piston Removal - Polaris Outlaw 500 Service Manual

Cylinder and Piston Removal

NOTE: Follow engine disassembly procedures to
remove valve cover, camshafts and cylinder head.
Removal of clutch basket is required for this
procedure.
1. Using a 9/32" (7mm) Allen wrench, remove the rear cam
chain tensioner blade from the cylinder.
2. Loosen the 3 oil pipe banjo bolts, remove the bolts and
sealing washers. Remove the pipes.
3. Tap cylinder lightly with a plastic hammer in reinforced
areas until loose.
4. Rock cylinder forward and backward and lift it from the
crankcase, exposing the piston and connecting rod. Support
piston with Piston Support Block (PN 2870390).
5. Remove dowel pins from crankcase.

Piston Removal

1. Remove circlip. Note piston directional aid that is pointing
toward the left (stator) side of engine.
Directional Aid
2. Remove piston circlip and push piston pin out of piston. If
necessary, heat the crown of the piston slightly with a
propane torch to aid removal.
IMPORTANT: Do not apply heat to the piston rings.
The ring may lose radial tension.
3. Remove top compression ring:
*Using a piston ring pliers: Carefully expand ring and lift
it off the piston.
*By hand: Placing both thumbs as shown, spread the ring
open and push up on the opposite side. Take care to not
scratch the ring lands.
IMPORTANT: Do not expand the ring more than the
amount necessary to remove it from the piston, or the
ring may break.
ENGINE
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