5.19
Engine and Cooling Systems
5
600 HO Carbureted Pistons / Crankshaft
Disassembly / Assembly Process
1. To remove the pistons, follow the process for removing the
cylinder head and cylinders from the engine.
2. To remove the crankshaft, follow the process for
disassembling the crankcase assembly.
3. With the piston out of the cylinder, remove one of the c-
clips and discard. Never re-use piston c-clips.
4. Push the piston pin out of the piston and upper rod bearings.
Inspect the pin for galling and abnormal wear. Inspect the
needle bearing by feel and replace as required.
5. New pistons are supplied with new rings and a piston pin.
It is recommended that new needle bearings be installed as
well.
6. When installing a new piston, insert one c-clip into the
piston making sure the open end is 180° opposite of the
groove opening.
7. Apply a liberal amount of Polaris two-stroke engine oil to
the needle bearings, piston pin and piston assembly.
8. Push the pin in to the piston, then through the needle
bearing. Install the remaining c-clip with the open end is
180° opposite of the groove opening.
NOTE: Always use new cylinder base gaskets.
9. Apply a liberal amount of Polaris two-stroke oil to the
cylinder wall. Align the piston ring gaps around the piston
locating pins. Compress the upper ring, then carefully slide
the cylinder down over the ring.
10. Compress the lower ring, then slide the cylinder down over
the ring.
PISTON
PISTON PIN
PISTON RINGS
C-CLIP
NEEDLE BEARINGS
PTO CRANKCASE SEAL
BEARINGS
BEARING
FLYWHEEL KEY
MAG CRANKCASE SEAL
Piston Matrix
Engine Model Piston PN Piston ID
S3273-6044-PF6F
2202258
(Subs to 2203319)
EK-2202b
S3274-6044-PF6F
S3466-6044-PU6F
2203319 EK-2202c
S3467-6044-PU6F
To Next Page
Loading...
Need help?
General
