3.62
9850045 R01 - 2020-2021 RANGER 1000 Service Manual
© Copyright Polaris Inc.
CYLINDER / PISTON SERVICE
REMOVAL
1. Remove the cylinder head. Refer to Cylinder Head
Removal and Installation page 3.41
2. Remove the upper crankcase. Refer to Upper
Crankcase Service page 3.54.
3. Rotate the engine so the cylinder is facing up.
4. Remove the Cylinder Holding & Camshaft Timing
Plate (PU-50563)
q
from the cylinder.
5. Carefully lift the cylinder and pistons from the upper
crankcase.
6. Remove the piston / connecting rod assemblies from
the cylinder.
IMPORTANT
If the pistons are to be reused, mark the pistons so they
are reassembled in the same cylinder bore and
direction from which they were removed (MAG / PTO).
INSTALLATION
CAUTION
Pistons must be installed into the cylinders with the
connecting rods attached.DO NOT attempt to service
the cylinder or pistons without disassembling the
crankcase. Although you can remove the cylinder and
pistons without disassembly, you will not be able to
reassemble the engine because of the unique cylinder
skirt and crankcase design.
NOTICE
If the pistons are being reused, reassemble in the same
cylinder bore and direction from which they were
removed (MAG / PTO).
New pistons are directional (intake vs. exhaust), but
can be placed in either cylinder.
1. Apply clean engine oil to each piston assembly,
cylinder bore and bottom tapered portion of each
cylinder sleeve.
2. Verify that all ring end gaps are correctly located on
each piston.
ENGINE / COOLING / EXHAUST
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