3
9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service
Manual
© Copyright Polaris Industries Inc.
3.115
NOTE
Always replace plain bearings when the crankcase or
connecting rods have been disassembled. Refer to
Bearing Selection Identification Letters and Numbers,
page 3.121.
CYLINDER INSPECTION
1. Lay a straight edge
q
across the top surface of the
cylinder at several different points 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.
3. 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″ down
from top, the middle, and 1.54″ up from bottom).
Record measurements. If cylinder is tapered or out
of round beyond 0.001", the cylinder must be
replaced.
MEASUREMENT
Cylinder Taper:
.001″ (0.025 mm)
Cylinder Out of Round:
.001″ (0.025 mm)
MEASUREMENT
Standard Bore Size:
3.6614 ± .0003" (93 mm ± 0.008 mm)
ENGINE / COOLING SYSTEM
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