Piston / Connecting Rod Assembly; Cylinder Installation - Polaris RANGER 500 2017 Service Manual

ENGINE / COOLING SYSTEM

PISTON / CONNECTING ROD ASSEMBLY

1. Lubricate connecting rod small end, piston pin bore
and piston pin with engine oil.
IMPORTANT
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.
NOTICE
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).
IMPORTANT
Never re-use a piston pin circlip.
3. When installing the piston, ensure the piston marking
arrow is positioned towards the exhaust side of the
engine.
3.60
q
4. Place piston on connecting rod
e
through rod and piston until it seats against the
installed circlip.
NOTICE
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.
IMPORTANT
DO NOT apply heat to piston rings or a loss of radial
tension could result.
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.
NOTICE
Base gasket and surfaces must be DRY and oil free.
Use care upon assembly to keep oil away.
9850043 R01 - 2017-2021 RANGER 500 / 570 Service Manual
w
. Push piston pin
r
with gap at the top
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