Piston and Segment Installation:
- Be careful never to install chrome segments in chrome, nikasil or electrofusion cylinders.
- Before installation, slide each ring into the cylinder bore and measure the end gap to eliminate the possibility of ring bottoming. An acceptable gap is between .010 and .025. If the gap is inadequate, gently file to the recommended measurement.
Consult the “Cylinder/Piston Clearance” guide.
- Clean and lubricate all parts with 10W30 engine oil.
- Install the piston with the arrow pointing toward the exhaust (except for certain POLARIS models. The arrow should then point toward the magneto).
- Place the retaining rings carefully, without bending, forcing or twisting them. Make sure they sit securely in the grooves and that the openings are positioned downwards.
- Place the segments on the corresponding pistons. Lubricate and check that the ends can close completely at the locating pins.
- Install the new base gasket, compress the ring, and slide the cylinder onto the piston. Before installing the cylinder head, rotate the crankshaft by hand to ensure that the pistons and rings move freely in the cylinders.