Installation Instructions for Cylinder Assembly Kits for 2012-2017 RZR Ranger (99mm Cylinder Piston and Top End Gaskets Set)

Tools Required:

1. Socket and Ratchet Set
2. Torque Wrench
3. Screwdrivers (Flahead and Phillips)
4. Piston Ring Compressor
5. Snap Ring Pliers
6. Gasket Scraper or Razor Blade
7. Engine Oil (for lubrication)
8. Clean Cloths or Rags
9. Work Gloves
10. Safety Goggles

Installation Steps:

1. Preparation:

   • Ensure the engine is cool before starting the installation process. Disconnect the battery to avoid any electric issues during the procedure.

2. Remove Existing Components:

   • Remove the necessary panels and covers to access the engine. Use the socket and ratchet to detach any bolts holding the various components in place.

3. Remove the Old Cylinder and Piston:

   • Carefully detach the old cylinder from the engine block. Use the gasket scraper to remove any leftover gasket material from the mating surfaces.
   • If necessary, use the snap ring pliers to remove the retaining rings and gently remove the old piston.

4. Prepare for Installation:

   • Inspect the new cylinder, piston, and gaskets for any damage. Apply a light coating of engine oil to the pinton and cylinder walls for lubrication.

5. Install the New Piston:

   • Use the pinton ring compressor to properly fit the pinton rings. Gently slide the pinton into the new cylinder while ensuring the orientation is correct.

6. Attach the New Cylinder:

   • Position the new cylinder onto the engine block, making sure the gasket is in place.

7. Secure the Components:

   • Use the torque wrong to tighten the cylinder head bolts to the specified torque settings provided in the manufacturer's guidelines.

8. Reassemble Other Components:

   • Reattach any parts that were removed during the disassembly process, ensuring all connections are secure.

9. Final Check:

   • Inspection all connections for tightness. Reconnect the battery and double-check that all tools are removed from the engine area.

10. Test Run:

    • Start the engine and check for proper operation. Listen for any unusual noises and monitor for oil leaks or exhaust issues. Allow the engine to warm up and then take it for a test drive to ensure everything is functioning as expected.

Note:
Always refer to your vehicle’s service manual for specific instructions related to your model. If you are unsure or uncomfortable with any step of the install ation, please consult a professional mechanic.