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  1. Clean ALL new and old parts thoroughlyto assure no foreign debris is present. After cleaning with solvent/and or Soapy Water. Coat the cylinder walls with 2 stroke oil and then wipe out the oil with a clean rag. This oil will pull even more debris from the plating leave the excess oil
  2. Set Ring End Gap:
    1. Place 1 ring in cylinder                                                                
    2. Level ring in cylinder by using the piston as a leveling device
    3.  Measure gap with a feeler gauge. Should be between .017”-.020”                    
    4.  Using a wet-stone or something similar, gently grind on one end of the ring until desired clearance is obtained.      
    5.  Repeat process for each ring.                                          
  3.  MAKE SURE you know which rings are gapped for which cylinders! Install rings on pistons
  4. Install pistons and top end bearing onto connecting rods. Ring ends ALWAYS point to the intake.
  5. Install wrist pin and cir-clips onto piston.
  6. Install base gasket. To assure a flat seal. MAKE SURE case and cylinder base is free of ANY grease or     foreign debris. USING NO SEALER!! Install RKT Supplied gasket.
  7. Install MAG cylinder. Hand-tighten bolts. Make sure the gasket has not been displaced during this process. Install PTO cylinder using the same cautions as above.Install RAVE gaskets (not supplied) under each RAVE guillotine. Make sure RAVE base housing has exhaust supply hole line up with supply hole on cylinder.
  8. 800R: Install E-RAVE assemblies with gaskets (not supplied) onto each cylinder. Connect all hoses to E-Raves and make sure the hoses are secure on the solenoids. Make sure guillotines screw in STRAIGHT with respect to the diaphragm. It is very easy to get them installed crooked.  Install Teflon tape on coolant plugs and install. These are located on the cylinder near each RAVE Valve
  9. Torque cylinder bolts to 27 ft/lbs and then final torque bolts to 32ft/lbs (Series III).. 40ft/lb final torque on the Mono Block 800R Cylinder.
  10. Install Head at 22 ft/lbs torque
  11. Do not run the BR9ECS plug run the BR9EYA plugs (Arctic Cat) gap the plug @.020”
  12. PREMIX a 125:1 oil ratio in 1st tank of fuel. RKT Recommends to always premix at 150:1 in addition to your oil injection system.
  13. IMPORTANT: DO NOT USE ANY non, RK Tek, approved aftermarket silencer or pipe on this set-up. 
  14. Fire engine & check for base gasket leakage. Make sure no air pockets exist in the coolant system.
  15. Run engine at varying throttle positions for the 1st 50 miles checking piston wash and plug color (and adjusting accordingly), then ride it like normal! TARGET RPM: Series III: 8500  800R: 8300
  16. Jetting : If you have hooded needles (04 (Some 03 models) and newer) start with 380 mains and work down from there (probably end up at 350’s) richen needle 1 clip position.
  17. 800R Engine: Install 460 main jet. NOTE: this MAY be too big but will run well. Adjust later.
  18. DO NOT break in engine with ANY synthetic oil. Break in oil should be a GOOD mineral based oil Do not use Am-soil Oils!
  19. Clutching 800HO: Below 3000ft : Pur/Pur pri spring 414 ramp fully load the pins and set clicker to #2 setting.  If above 3000ft-> 413 or 415 ramp…start with 14g pin weight. Run the engine ON SNOW under load and adjust pin weight until the engine is pulling desired rpm...then click up 1-2 settings on your primary and you should be there. NOTE: do NOT assume that if you are correct rpm that you have the correct LOAD on the engine. ALWAYS load the engine UNTIL it will no longer pull the correct rpm. 800R SEA LEVEL: 441 or 414 ramp: 20-23g pin wt, Pur/Blu spring. Clicker #3.  MTN SET UP: 433 ramps with 17-20g pin wt. set at clicker 2. Use 43/47 Stock Helix. Adjust pin wt till proper running is achieved.