Wossner 8095D100 Piston Kit - Polaris Xplorer Xpress Big Boss 300 +1.00mm Oversize

Wossner Standard Series Forged 2-Stroke Piston Kit - +1.00mm Oversize

Restore the heavy-duty performance of your Polaris utility ATV with this Wossner Forged Piston Kit. Designed specifically for the Polaris 300cc 2-stroke engines used in the Xplorer, Xpress, Hawkeye, and Big Boss series, this +1.00mm oversize kit is the professional solution for cylinders that require boring to correct wear, ovality, or scoring. At Moto-House MX, we know these 300-series machines are the backbone of many outdoor tasks; upgrading to a Wossner forged piston provides superior structural integrity and heat resistance compared to original cast pistons, ensuring your Polaris remains a reliable workhorse.

This kit features a robust dual-ring configuration, which is essential for the high-torque, lower-RPM demands of utility ATVs. The dual rings provide enhanced heat dissipation from the piston to the cylinder walls and maintain a consistent compression seal for long-term durability. To ensure smooth operation and reduced engine noise, Wossner applies a permanent molybdenum disulphide skirt coating that minimizes friction and protects against piston rock. Precision-machined for a 75.50mm finished bore, this 75.43mm piston kit is the ultimate way to refresh your Polaris 300 engine.

Top Features: Wossner Polaris 300 Piston Kit

• +1.00mm Oversize (75.43mm): Engineered for cylinders being bored to a 75.50mm finished size to restore a perfect, fresh mechanical surface.
• Dual Ring Configuration: Provides superior cooling and a long-lasting compression seal, ideal for the utility and work-focused 300cc engine.
• Aerospace-Grade Forging: Significantly stronger and more resilient to thermal fatigue than standard cast pistons, offering a higher safety margin during heavy use.
• Low-Friction Skirt Coating: Permanent skirt treatment reduces internal drag and protects the cylinder wall, facilitating a smoother break-in period.
• Optimized Machining: Precisely crafted to reduce reciprocating mass while maintaining maximum strength in the crown and skirt walls.
• Complete Kit: Includes the high-performance forged +1.00mm piston, dual rings, wrist pin, and circlips.

Expert Pro-Tip: When moving to a +1.00mm oversize, it is critical that your cylinder is precision-bored and honed by a professional machine shop to exactly 75.50mm. This ensures the correct piston-to-wall clearance for a forged assembly. For a professional-grade rebuild, always install with a fresh top-end gasket kit and utilize premium 2-stroke oil to ensure your new forged assembly is properly protected from the first start.

Fitment List

Year Range	Vehicle Brand	Vehicle Model
1994-2000	Polaris	Xplorer 300 / 4x4
1994-2000	Polaris	Xpress 300 / 4x2
1994-2000	Polaris	Hawkeye 300 / 4x2 / 4x4 / LE / Camo
1994-2000	Polaris	Big Boss 300 6x6
1994-1995	Polaris	300 2x4 / 4x4

Frequently Asked Questions

Q: Why should I choose Wossner for my Polaris 300?
A: Wossner is a leader in forged piston technology. Forged pistons are much denser and more durable than the cast pistons originally found in many older ATVs, making them less likely to crack or fail under the high-heat conditions of utility work.

Q: Is boring the cylinder necessary for this kit?
A: Yes. Because this is a +1.00mm oversize piston, your cylinder must be professionally bored and honed to 75.50mm to accommodate the larger diameter and provide the correct clearance.

Q: Does this kit include the wrist pin bearing?
A: The kit includes the forged piston, rings, pin, and clips. The small-end needle bearing is sold separately. We highly recommend replacing the bearing during every top-end rebuild to ensure engine longevity.

Recommended Pairings

• Complete Top End Gasket Set: Vital for ensuring a leak-free seal and proper engine timing.
• High-Quality 2-Stroke Lubricant: Keep your new forged piston protected during the critical break-in and throughout its service life.

Restore your machine’s power and precision today. Buy now at Moto-House MX!

Moto-House MX – Choice of Champions – is located in Clermont/Montverde, FL. The Best Motocross/UTV & ATV Shop in Central Florida. Stop by our local store in Montverde, FL or enjoy lightning-fast shipping across the USA.