3
9928491 R04 - 2017-2018 RZR XP Turbo / XP4 Turbo Service Manual
© Copyright Polaris Industries Inc.
3.75
CAUTION
The pistons ARE directional. The relief pockets in the
pistons must face the intake side and the arrow points
towards the exhaust side.
1. Apply clean engine oil to each piston assembly
q
and cylinder bore prior to installation.
2. Verify that all ring end gaps are correctly located on
each piston (see Piston Ring Installation, page 3.73).
3. Carefully compress the piston rings with your fingers
and install the piston / connecting rod assemblies into
the cylinder from the top side.
NOTE
Use a slight front to back rocking motion until all rings
are captive in cylinder.
4. Rotate the engine so the crankcase to cylinder
mounting surface is facing up.
5. 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.
6. Reinstall dowel pins in crankcase if previously
removed.
7. Install a new cylinder base gasket.
8. Carefully place the cylinder and pistons into the upper
crankcase.
9. Install the Cylinder Holding & Camshaft Timing Plate
(PU-50563)
r
onto the cylinder. The cylinder holding
tool retains the cylinder and pistons when the engine
is rotated.
CRANKSHAFT INSTALLATION
NOTE
Whether installing a new crankshaft or re-installing the
original, refer to the bearing selection charts (see
Crankshaft Main Bearing Selection, page 3.72 and
Connecting Rod Bearing Selection, page 3.72.
1. Rotate the engine so the cylinder is facing down.
2. Clean the bearing bore surfaces of upper crankcase
(main bearings), connecting rods and connecting rod
caps.
ENGINE / COOLING SYSTEM
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