3.10
ENGINE
PISTON IDENTIFICATION
The piston is identified by the marking ES30A.
Note the directional and identification marks when
viewing the pistons from the top. The letters “IN” must
always be toward the intake side of the engine.
Piston rings must be installed correctly to ensure engine
performance. The numbers or letters on all rings (except
oil control rings) must be positioned upward. See text for
oil control ring upper rail installation. Use the information
below to identify pistons and rings.
PISTON RING IDENTIFICATION
The piston ring profile is shown below. Install top and
second ring with marking UP. Refer to text for oil control
ring installation.
ACCESSIBLE COMPONENTS
The following components can be serviced or
removed with the engine installed in the frame:
•Flywheel
• Alternator/Stator
• Starter Motor/Starter Drive
• Oil pump
• Rocker Arms / Rocker Shaft
• Camshaft
• Cam Chain and Sprockets
• Cylinder
• Cylinder Head
•Valves
• Carburetor
• Piston/RIngs
The following components require engine removal for
service:
• Starting Clutch (transmission removal required)
• One-Way Clutch (engine braking)
• Crankshaft
• Crankshaft Main Bearings
• Counter Balance Shaft or Bearings
• Crankcase
• Transmission
NOTE: Crankshaft components are not serviceable.
Replace crankshaft as an assembly.
ENGINE SERVICE
ENGINE REMOVAL
NOTE: The engine removal procedure described
below removes the engine and transmission as an
assembly, and the engine is then removed from the
transmission case. The transmission can be removed
separately from the engine (see Transmission
Removal procedure in this chapter).
1. Clean work area.
2. Thoroughly clean the ATV engine and chassis.
3. Disconnect battery cables at battery.
4. Drain engine oil.
5. Disconnect spark plug high tension lead.
6. Remove the following parts:
•Seat
• Left and Right Side Covers
• Rear cab
7. Remove CVT cover and both clutches (refer to CVT
Engine Model
No.
Oversize
Available (mm)
Standard
Piston
Identification
ES300PFE010
.25mm
.50mm
Valve Pocket to
Rear
(Intake Side)
Piston Ring
Installation
Note
Profile
TOP RING Mark Faces UP
Inner Bevel;
Barrel Face
SECOND RING Mark Faces UP
Undercut;
Taper Face
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