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9924707 - 2013–2014 RZR 800 Service Manual
© Copyright 2013 Polaris Sales Inc.
Valve Lifter Removal / Inspection
1. Remove the valve lifters by reaching into the
crankcase and pushing the lifter up through the lifter
bore by hand.
2. Thoroughly clean the lifters in cleaning solvent and
wipe them with a clean, lint-free cloth.
3. Mark the lifters with a white pen if using the lifters for
reassembly. This will ensure that the lifters are
properly placed during engine reassembly.
4. Check the lifters for wear or scores.
5. Check the bottom end of lifter to make sure that it
has a slight convex.
6. If the bottom surface has worn flat, it may be used
with the original camshaft only.
NOTE: Lifters that are scored, worn, or if the
bottom is not smooth should be replaced with
new lifters and cam as an assembly. If replacing
the lifters, the camshaft should also be replaced.
Piston Removal
1. Remove the circlip. Mark the piston with a white pen
to ensure proper orientation (if reused) during
assembly.
NOTE: If the pistons are to be reused,
reassemble the pistons in the same cylinder and
direction from which they were removed.
NOTE: New pistons are non-directional and can
be placed in either cylinder.
2. Remove piston circlip and push piston pin out of
piston. If necessary, heat the crown of the piston
slightly with a propane torch. CAUTION: Do not
apply heat to the piston rings. The ring may lose
radial tension.
3. Remove top compression ring:
*Using a piston ring pliers: Carefully expand ring
and lift it off the piston. CAUTION: Do not expand
the ring more than the amount necessary to remove
it from the piston, or the ring may break.
*By hand: Placing both thumbs as shown, spread
the ring open and push up on the opposite side. Do
not scratch the ring lands.
ENGINE
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