3.60
9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service
Manual
© Copyright Polaris Industries Inc.
CYLINDER / PISTON REMOVAL
CAUTION
Pistons must be removed from the cylinders with the
connecting rods attached.
DO NOT attempt to service the cylinder or pistons
without disassembling the crankcase. Although you can
remove the cylinder and pistons without disassembly,
you will not be able to reassemble the engine because
of the unique cylinder skirt and crankcase design.
1. Perform “ENGINE DISASSEMBLY / INSPECTION -
TOP END” and the “ENGINE DISASSEMBLY /
INSPECTION - LOWER END” procedures.
2. Rotate the engine so the cylinder is facing up.
3. Remove the Cylinder Holding & Camshaft Timing
Plate (PU-50563) from the cylinder.
4. Carefully lift the cylinder and pistons from the upper
crankcase.
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).
CYLINDER INSPECTION
1. Lay a straight edge across the top surface of the
cylinder at several different points
q
and measure
warp by inserting a feeler gauge between the straight
edge and the cylinder surface. If warp exceeds the
service limit, replace the cylinder.
MEASUREMENT
Cylinder Warp Limit:
.002" (0.05 mm)
2. Inspect cylinder for wear, scratches, or damage.
NOTE
DO NOT hone the cylinders or attempt to repair a
damaged cylinder by honing.
ENGINE / COOLING SYSTEM
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