Hey there,
Ive got a 2002 Polaris Xplorer 400 and I have bored out the cylinder and got a new piston and rings. What is the best way to go about reinstalling the cylinder and piston? Should I install the Piston first and then slide the cylinder over the top of the piston and compressed rings???

 

Install the piston first,make sure the marks on the rings face up, and piston installed the right way! (open ends of rings face toward rear against ring stops on piston) You can slightly tilt cylinder to get better access to piston and rings,while squeezing the top ring slowly, slide into cylinder,then the second ring. Lightly oil the cylinder before you install. Don't forget the base gasket after piston installed,I've almost done this myself ! Good luck OPT

 

Thats just about what I had in mind. I was just havin trouble fittin the cylinder over the new rings and thought there might be a better way... I guess a tight fit ensures good compression.

Thanks.

 

And make sure you double check the piston pin retainer clips, if they arent seated in the groove, its good bye cylinder

 

its a one shot deal for sure to get it right. you didnt mention it but i'm sure the cyclinder got honed out after boring correct?

 

Also, make sure you are not using a synthetic blend of oil while oiling down cylinder and rings during installation, in addition use non synthetic oil during break in to properly seat rings

 

Is there a certain brand of oil I should use? Whats the best?

 

Straight non-synthetic, Injex, any brand that is non-synthetic, just coat your cylinder and piston liberally, don't be bashfull, and when brake in, make sure you mix plenty of oil in the Gas

 

hey thanks for the tips. got it started and sounds really strong,,,,but i must done something to the carburetor because right off start up the the idle rpms are at about half of what its got. :0 Ive messed with the idle adjuster and the throttle screw, but it really hasnt helped at all. any help?

-Caleb