3
3.55
9924874 R02 - 2014 RZR XP / XP 4 1000 Service Manual
© Copyright 2013 Polaris Industries Inc.
5. Remove the piston / connecting rod assemblies from
the cylinder.
NOTE: If the pistons are to be reused, mark the
pistons so they are reassembled in the same
cylinder bore and direction from which they were
removed (MAG / PTO).
Piston Disassembly / Inspection
NOTE: New pistons are directional (intake vs.
exhaust), but can be placed in either cylinder.
1. Note location of the piston circlip gap (Item 1) at the
top (12:00 position) or bottom (6:00 position).
2. Remove piston circlip and push piston pin out of
piston. If necessary, heat the crown of the piston
slightly with a heat gun if pin cannot be removed by
hand. Discard circlips.
CAUTION
DO NOT apply heat to piston rings or a loss of
radial tension could result.
3. Measure piston pin bore I. D. in two directions (90°
apart). Replace piston and piston pin if out of
specification.
Piston Pin Bore I.D.:
0.7877 - 0.7881" (20.009 - 20.018 mm)
Service Limit:0.7893" (20.05 mm)
ENGINE
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