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9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual
© Copyright Polaris Industries Inc.
3.35
PISTON / RINGS / CONNECTING ROD / CRANKSHAFT / BALANCE SHAFT
Piston
Piston - Standard O.D. - Measured 90 degrees to pin,
0.51 in. (13 mm) up from piston skirt. See text.
3.6592 ± 0.0003" (92.950 ± 0.008 mm)
Piston Pin Bore I.D. (Standard) 0.7876" - 0.7878" (20.004 - 20.009 mm)
Piston Pin Bore I.D. (Service Limit) 0.7893" (20.05 mm)
Piston Pin
Piston Pin O.D. (Standard) 0.7872" - 0.7874" (19.995 - 20.000 mm)
Piston Pin O.D. (Service Limit) 0.7866" (19.98 mm)
Piston Ring
Installed
Gap
Top Ring (Standard) 0.008" - 0.014" (0.20 - 0.36 mm)
Top Ring (Service Limit) 0.020" (0.5 mm)
Second Ring (Standard) 0.015" - 0.025" (0.37 - 0.63 mm)
Second Ring (Service Limit) 0.028" (0.70 mm)
Oil Control Rails (Standard) 0.010" - 0.040" (0.25 - 1.02 mm)
Oil Control Rails (Service Limit) 0.059" (1.50 mm)
Ring to
Groove
Clearance
Top Ring (Standard) 0.0012" - 0.0037" (0.030 - 0.095 mm)
Second Ring (Standard) 0.0012" - 0.0030" (0.030 - 0.076 mm)
Service Limit
0.0047" (0.12 mm)
Connecting Rod
Connecting Rod Small End I.D. (Standard) 0.7879" - 0.7884" (20.015 - 20.025 mm)
Connecting Rod Small End I.D. (Service Limit) 0.7897" (20.06 mm)
1 - Marking Connecting Rod Big End Bore I.D. 1.7318" - 1.7321" (43.989 - 43.996 mm)
2 - Marking Connecting Rod Big End Bore I.D. 1.7321" - 1.7323" (43.996 - 44.003 mm)
3 - Marking Connecting Rod Big End Bore I.D. 1.7323" - 1.7326" (44.003 - 44.010 mm)
Crankshaft
B - Marking Main Journal O.D. (Standard) 1.6140" - 1.6143" (40.996 - 41.004 mm)
G - Marking Main Journal O.D. (Standard) 1.6137" - 1.6140" (40.988 - 40.995 mm)
Y - Marking Main Journal O.D. (Standard) 1.6134" - 1.6137" (40.980 - 40.987 mm)
Main Journal O.D. (Service Limit) 1.6126" (40.960 mm)
B - Marking Rod Journal O.D. (Standard) 1.6118" - 1.6122" (40.942 - 40.950 mm)
G - Marking Rod Journal O.D. (Standard) 1.6115" - 1.6118" (40.934 - 40.941 mm)
Y - Marking Rod Journal O.D. (Standard) 1.6112" - 1.6115" (40.926 - 40.933 mm)
Rod Journal O.D. (Service Limit) 1.6104" (40.906 mm)
Crankshaft Runout Limit (PTO and MAG) Less than 0.001" (0.025 mm)
Auxiliary Sprocket Installed Depth 4.9527" ± 0.0078" (125.8 ± 0.2 mm)
Balance Shaft
Bearing Journal O.D. (Standard) 1.4939" - 1.4946" (37.946 - 37.962 mm)
Bearing Journal O.D. (Service Limit) 1.4921" (37.900 mm)
ENGINE / COOLING SYSTEM
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