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9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual
© Copyright 2014 Polaris Industries Inc.
Cylinder / Piston 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.
NOTE: If the pistons are being reused, reassemble
in the same cylinder bore and direction from which
they were removed (MAG / PTO).
New pistons are directional (intake vs. exhaust), but
can be placed in either cylinder.
1. Apply clean engine oil to each piston assembly,
cylinder bore and bottom tapered portion of each
cylinder sleeve.
2. Verify that all ring end gaps are correctly located on
each piston (see Chapter 3 – Piston Ring
Installation, page 3.64).
3. Note the piston orientation mark (arrow) located on
top of the piston. Arrow should point toward the
exhaust side.
NOTE: Orientation arrow is also located on the
bottom side of piston as an additional reference.
4. Carefully compress the piston rings with your fingers
and install the piston / connecting rod assemblies
into the cylinder from the bottom side.
NOTE: Use a slight front to back rocking motion
until all rings are captive in cylinder and past the
cylinder sleeve opening
.
5. Rotate the engine so the crankcase to cylinder
mounting surface is facing up.
6. Clean base gasket sealing surface on cylinder and
crankcase to remove all oil and grease.
NOTE: Base gasket and surfaces must be DRY
and oil free. Use care upon assembly to keep oil
away.
7. Reinstall dowel pins in crankcase if previously
removed.
8. Install a new cylinder base gasket.
9. Verify piston orientation (arrow pointing toward
exhaust) one last time prior to installation.
ENGINE / COOLING SYSTEM
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