I’m attempting to do a rebuild on my 800 rzr. As I was putting the cylinder on the pistons slipped out the bottom of it. They were pretty much level with the block so I could not hardly get my fingers in there to pull them up enough to remove them and start over.

I broke 2 piston clips by simply taking them off the pistons in the process of trying to get a finger hold without pulling on the rings. I put the machine in gear and rolled it a bit but that did not help. Well then I had this hair brained idea to crank the engine just a bit to pop the pistons up. It was either that or use some sort of tool to pull them up.

If you are done laughing you can imagine what happened. Though I tried to do it just barely they shot up and one slammed back hard and chipped the skirt off the piston. It also dinged the inside edge of crank shaft as well.

So I’m wondering:

1. Can this piston be used still or do I run the risk of it catching on the cylinder? I’m assuming no as I figured it would at least make if off balance?
2. Did I just get some crap rings (it was the OEM ring/piston kit)? I did not torque the rings any more than to gently pull them off. Seems they should not break that easily. One of them actually broke in 2 places.
3. Is the damage to the crankcase going to affect the piston? I’m thinking that the bottom of the cylinder seats inside that so it should be a non issue?

I’ve attached some pictures that kinda show what happened. Now I’m probably screwed out of riding this weekend. Wish I knew someone locally that I could trust to finish this project. Guess trying to save me some money has ended up costing more.

Appreciate the advice!

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