2000 Polaris Indy 500 / 600 snowmobile service manual, Page 97Get this manual
ENGINES 500 Domestic Case Reed Twin Assembly, Cont16Assemble engine mount straps to crankcase
Engine Mount Strap Torque: 44-48 ftlbs(60-66 Nm) 17Lubricate main bearing oil holes with Polaris Premium Cycle or Premium Gold engine oil and rotate crankshaft to distribute oil evenly18Install new C-clip in both pistons (inside) with gap facing downBe sure clip is fully seated in groove19Lubricate and install new connecting rod small end bearing in rod20Install piston with arrow facing exhaust (ring locating pins should be facing intake)Warming the piston may help to ease installation of pin21Install remaining C-clip with gap downBe sure both clips are fully seated in the groove22Install new base gasketBe sure gasket surface is clean and free of nicks, burrs, or scratches23Lubricate and install piston rings on piston with mark on end of ring facing upward24Place piston support under skirt and lubricate pistons and cylinders thoroughly25Align ring end gaps with locating pins and compress ringsInstall cylinder carefully with gentle front to rear rocking motionInstall cylinder base nuts looselyDo not tighten them at this timeRepeat Steps 22-25 for other cylinderCAUTION: Do not twist or force cylinder during installation26Install new cylinder head O-rings and install cylinder headMake sure O-rings are properly seated in groovesApply light film of grease to hold O-rings in place if necessaryStraight Edge