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9930588 R02 - 2017-2020 RZR 900 900/S 900/S4 1000/S 1000/S4 Service Manual
© Copyright Polaris Industries Inc.
PISTON DISASSEMBLY / INSPECTION
(1000)
NOTICE
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.
3. Measure piston pin bore I. D. in two directions (90°
apart). Replace piston and piston pin if out of
specification.
MEASUREMENT
Piston Pin Bore I.D.:
.7877 - .7881" (20.009 - 20.018 mm)
Service Limit:
.7893" (20.05 mm)
4. Measure piston pin O.D. in two directions (90° apart)
at three locations on the length. Replace piston and
piston pin if out of specification.
MEASUREMENT
Piston Pin O.D.:
.7873 - .7875" (20.000 - 20.005 mm)
Service Limit:
.7866" (19.98 mm)
ENGINE / COOLING SYSTEM
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