3
9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service
Manual
© Copyright Polaris Industries Inc.
3.125
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.
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.
If reinstalling the original connecting rods, orientate the
rods the same as when removed. If new connecting
rods are being installed, they can be installed either
way (there is no piston pin offset in the rod), however it
is recommended they be installed with rods facing the
same direction.
3. Place piston
q
on connecting rod
w
. Push piston pin
e
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.
CAUTION
DO NOT apply heat to piston rings or a loss of radial
tension could result.
4. Install the remaining circlip
r
with gap at the top
(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.
ENGINE / COOLING SYSTEM
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