3
9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service
Manual
© Copyright Polaris Industries Inc.
3.61
3. Inspect taper and out of round with a dial bore
gauge.
4. Inspect cylinder for taper and out of round with a dial
bore gauge. Measure in two different directions (front
to back and side to side), on three levels (0.59 in.
down from top, the middle, and 1.54 in. up from
bottom). Record measurements. If cylinder is
tapered or out of round beyond the service limit, the
cylinder must be replaced.
MEASUREMENT
Cylinder Taper:
Service Limit: 0.001" (.025 mm)
Cylinder Out of Round:
Service Limit: 0.001" (.025 mm)
MEASUREMENT
Standard Bore Size:
3.6614 ± .0003" (93 mm ± .008 mm)
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
q
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.
ENGINE / COOLING SYSTEM
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