3
9926806 R03 - 2015 - 2016 RANGER ETX / 570 2-SEAT 2015 - 2016 RANGER 570 CREW Service Manual
© Copyright Polaris Industries Inc.
3.59
PISTON / CONNECTING ROD ASSEMBLY
IMPORTANT
If installing the piston onto the connecting rod, you
cannot use special tools: PV-43570–1 (Piton Ring
Compressor Pliers) and PA-51457 (Piston Ring Band)
to compress the rings when installing the cylinder. The
rings must be fitted into the cylinder by hand.
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.
2. Install a new piston circlip
q
into the MAG (stator)
side of piston with the gap at the 12:00 position.
3. When installing the piston, the piston marking “∆” is
points towards the MAG (stator) side of the engine.
4. Place piston
w
on connecting rod
r
. Install piston
pin
e
through connecting rod
r
and piston until it
seats against the previously installed piston circlip.
NOTE
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.
CAUTION
DO NOT apply heat to piston rings or a loss of
radial tension could result.
5. Install the remaining circlip
q
with gap at the 12:00
position. Push the piston pin in both directions to
make sure the clips are properly seated in the
groove.
CYLINDER INSTALLATION – PISTON
INSTALLED ON CONNECTING ROD
1. Clean base gasket sealing surface on cylinder and
crankcase to remove all oil, grease, or old sealant.
2. Install a new base gasket.
NOTE
Base gasket and surfaces must be dry and oil free.
Match gasket and deck profiles during assembly. If
gasket is installed incorrectly, it will hang over the edge
of the crankcase.
3. Apply clean engine oil to cylinder bore and bottom
tapered portion of cylinder sleeve.
4. Verify all ring end gaps are correctly located on the
piston. Place cam chain and guides in alignment with
chain tunnel.
ENGINE / COOLING SYSTEM
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