3.82
9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual
© Copyright Polaris Industries Inc.
PISTON / CYLINDER 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.
IMPORTANT
If the pistons are being reused, reassemble in the same
cylinder bore and direction from which they were
removed (MAG / PTO).
CAUTION
The pistons ARE directional. The relief pockets in the
pistons must face the intake side and the arrow points
towards the exhaust side.
1. Apply clean engine oil to each piston assembly
q
and cylinder bore prior to installation.
2. Verify that all ring end gaps are correctly located on
each piston (see Piston Ring Installation page 3.80).
3. Carefully compress the piston rings with your fingers
and install the piston / connecting rod assemblies into
the cylinder from the top side.
NOTICE
Use a slight front to back rocking motion until all rings
are captive in cylinder.
4. Rotate the engine so the crankcase to cylinder
mounting surface is facing up.
5. Clean base gasket sealing surface on cylinder and
crankcase to remove all oil and grease.
NOTICE
Base gasket and surfaces must be DRY and oil free.
Use care upon assembly to keep oil away.
6. Reinstall dowel pins in crankcase if previously
removed.
7. Install a new cylinder base gasket.
8. Carefully place the cylinder and pistons into the upper
crankcase.
ENGINE / COOLING SYSTEM
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