Piston / Connecting Rod Assembly; Cylinder Installation - Polaris RANGER 500 2018 Service Manual

PISTON / CONNECTING ROD ASSEMBLY

1. Lubricate connecting rod small end, piston pin bore
and piston pin with engine oil.
CAUTION
Do not re-use circlips. Circlips become deformed during
the removal process.
Do not compress the new clip more than necessary to
prevent loss of radial tension. Severe engine damage
may result if circlips are re-used or deformed during
installation.
NOTE
Stuffing a clean rag around the connecting rod after
cylinder is removed is helpful in keeping foreign objects
from falling into the crankcase.
2. Install a new circlip on one side of piston with gap at
the top (12:00 position) or bottom (6:00 position).
NOTE
Never re-use a piston pin circlip.
3. When installing the piston, be sure the piston marking
"EX" is positioned towards the exhaust side of the
engine.
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4. Place piston on connecting rod
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through rod and piston until it seats against the
installed circlip.
NOTE
Do not tap on pin or cause any sideways force to
connecting rod. Warm piston crown with a heat gun if
pin cannot be installed by hand, or use a piston pin
installation tool.
9928485 R01 - 2017-2018 RANGER 500 / 570 Service Manual
© Copyright Polaris Industries Inc.
DO NOT apply heat to piston rings or a loss of
5. Install the remaining circlip
(12:00 position) or bottom (6:00 position). Push the
piston pin in both directions to make sure the clips are
properly seated in the groove.

CYLINDER INSTALLATION

1. Clean base gasket sealing surface on cylinder and
crankcase to remove all oil, grease, or old sealant.
2. Install a new base gasket.
Base gasket and surfaces must be DRY and oil free.
3. Slide a commercially available Piston Support Block
under piston skirt to support piston during cylinder
installation.
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. Push piston pin
4. Apply clean engine oil to cylinder bore and bottom
tapered portion of cylinder sleeve.
ENGINE / COOLING SYSTEM
CAUTION
radial tension could result.
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with gap at the top
NOTE
Use care upon assembly to keep oil away.
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