3.64
ENGINE / COOLING
9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual
© Copyright 2012 Polaris Sales Inc.
4. Carefully compress the piston rings with your fingers
and install the piston / connecting rod assemblies into
the cylinder from the bottom side.
NOTE: Use a slight front to back rocking motion
until all rings are captive in cylinder and past the
cylinder sleeve opening.
5. Rotate the engine so the crankcase to cylinder
mounting surface is facing up.
6. Clean base gasket sealing surface on cylinder and
crankcase to remove all oil and grease.
NOTE: Base gasket and surfaces must be DRY and
oil free. Use care upon assembly to keep oil away.
7. Reinstall dowel pins in crankcase if previously
removed.
8. Install a new cylinder base gasket.
9. Verify piston orientation (arrow pointing toward
exhaust) one last time prior to installation.
10. Carefully place the cylinder and pistons into the upper
crankcase.
11. Install the Cylinder Holding & Camshaft Timing Plate
(PU-50563) onto the cylinder. The cylinder holding
tool retains the cylinder and pistons when the engine
is rotated.
Crankshaft Installation
IMPORTANT: Whether installing a new crankshaft or
re-installing the original, refer to the bearing selection
charts (see “Crankshaft Main Bearing Selection” and
“Connecting Rod Bearing Selection” procedures in
this chapter).
1. Rotate the engine so the cylinder is facing down.
2. Clean the bearing bore surfaces of upper crankcase
(main bearings), connecting rods and connecting rod
caps.
3. Align tab of new main bearing (A) with the slot in main
bearing bore of crankcase. Press bearing insert firmly
into place. Repeat for all main bearings.
Install pistons
past the cylinder
sleeve opening
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