Table of Contents
ENGINE / COOLING SYSTEM
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.
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2. Install a new circlip
at the top (12:00 position).
IMPORTANT
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.
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3. Place piston
on connecting rod
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through rod and piston until it seats against the
installed circlip.
3.74
on one side of piston with gap
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. Push piston pin
CAUTION
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.
DO NOT apply heat to piston rings or a loss of radial
tension could result.
4. Install the remaining circlip
(12:00 position). Push the piston pin in both directions
to make sure the clips are properly seated in the
groove.
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).
9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual
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with gap at the top
© Copyright Polaris Industries Inc.
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