Polaris Genesis 2000

ENGINE
Disassembly/Inspection - Polaris Engines
20 . Loosen cylinder base nuts evenly in a criss cross
pattern. Support pistons while removing cylinders.
NOTE: Each cylinder and piston should be marked
to keep all parts together as a matched set. If parts
are to be reinstalled keep piston pins and top bear
ings together with their respective cylinders. Always
use new piston pin C-clips upon reassembly.
21 .Inspect each cylinder for wear, scratches, or
damage. If no damage is evident, measure cylinder
for taper and out of round with a telescoping gauge
and micrometer or a dial bore gauge. Measure bore
1/2" down from top of cylinder in two directions - in
line with piston pin and 90p to the pin to determine if
bore is out of round. Repeat measurements at
bottom of cylinder to determine taper or out of round
at the bottom. Record all measurements.
NOTE: If cylinders are worn or damaged refer to page
4.43-4.44 for boring/honing and port chamfer informa
tion.
22 . Remove piston circlips carefully using an awl, scribe,
or very small screwdriver.
The circlip is under tension. Wear eye protection. Keep
your thumb on the edge of the clip to prevent it from
springing out.
23 . Remove piston pin using piston pin puller and piston.
If necessary, heat piston crown slightly with a
propane torch.
Do not apply heat to the piston rings. The rings may lose
radial tension.
3100
4.20
Polaris Sales Inc.