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Thread: How to guide?

  1. #1
    2000 Polaris Pro 1200 rdizz81's Avatar
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    How to guide?

    i have been searching the threads i cant find a "How to guide" on removing the piston jugs on a polaris pro 1200

    anyone?


  2. #2
    ryandi2's Avatar
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    take water rail off.. then unbolt the hend cover of what ever cyl you want to take off, then take the bolts off the dome that is under the red cover. and there you go..

    check the o rings.. if they are good you can re use them

  3. #3
    2000 Polaris Pro 1200 rdizz81's Avatar
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    Quote Originally Posted by ryandi2 View Post
    take water rail off.. then unbolt the hend cover of what ever cyl you want to take off, then take the bolts off the dome that is under the red cover. and there you go..

    check the o rings.. if they are good you can re use them

    that has been done what i cant find is a how to on installaling a new piston kit...

    how do i remove the old piston?

  4. #4
    You need to remove the 4 nuts at the base of the jug that hold the jug to the cases. The nuts on the intake side can be reached from the top with socket and a wobble extension or an extension and a u-joint. On the exhaust side, you typically have to remove the exhaust manifold to get to the base nuts. You can't get a socket on them from the top - you need to use a wrench from the side.

    With those 4 nuts removed, you can slide the jug straight up and off the piston (remove the spark plug if you don't have the dome already off - this will remove the vacuum the piston will be making in the bore.)

    The wrist pin is held in by a retainer ring on either side of the piston. There's a little notch on the piston that you can us to get under the retainer ring. I use a small pick to get under the retainer and pop it out. Careful, as the retainer rings like to fly when they spring out. With the retainer ring out, the wrist pin may slide right out. Sometimes they need a little persuasion - I use a long socket that's just a little smaller diameter than the pin and tap it out with a small hammer. It should take much force to remove the wrist pin. Be careful no to lose or drop the wrist bearing when the pin pops out.

    Installation is just in reverse of removal.

  5. #5
    2000 Polaris Pro 1200 rdizz81's Avatar
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    seems pretty straight foward...


    now the issue im coming across is the exhaust pipe (large red pipe)

    the 4 bolts on the top are almost impossible to remove not only are they extreamly tight the inside bolts are covered by the hull and i really dont see a way to get in there....

  6. #6
    Quote Originally Posted by rdizz81 View Post
    seems pretty straight foward...


    now the issue im coming across is the exhaust pipe (large red pipe)

    the 4 bolts on the top are almost impossible to remove not only are they extreamly tight the inside bolts are covered by the hull and i really dont see a way to get in there....

    On all my domestics, I have to wedge something between the pope and the hull and actually spread the hull to get a socket on the pipe bolts. I usually use a piece of wood or the handle of my dead-blow hammer to bend the hull over enough to get the socket on it.


    If you don't have wobble extensions, I highly recommend picking up a set. They give you a little better clearance than a typical universal joint.


  7. #7
    2000 Polaris Pro 1200 rdizz81's Avatar
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    This Job may be beyond my expertise....

    thinking of finding someone to do it lol.

  8. #8
    2000 Polaris Pro 1200 rdizz81's Avatar
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    Allthough i just cant let this thing beat me lol

    Tony was telling me about a Crow Split wrench for the bolts on the base of the jug

    am i saying this correctly?

  9. #9
    Tony's Avatar
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    Crow's foot wrench.

    Where are you at now on the tear down? I'm sorry I haven't stopped by, my schedule is just jam packed right now.

  10. #10
    seaobin's Avatar
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    Swim team tonight, Dive meets Wed and Thursday, But Friday or Saturday morning, I could help

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