3.64
9926814 R08 - 2015-2016 RZR 900 2016 RZR S 1000 Service
Manual
© Copyright Polaris Industries Inc.
PISTON-TO-CYLINDER CLEARANCE
Measure piston outside diameter at a point 13 mm up
from the bottom of the piston, at a right angle to piston
pin bore.
Subtract measurement from maximum measurement
obtained in Step 4 of “Cylinder Inspection” procedure.
MEASUREMENT
Piston O.D. (Standard):
3.6592 ± .0003" (92.950 ± .008 mm)
MEASUREMENT
Piston to Cylinder Clearance:
.0014 - .0026" (.035 - .065 mm)
CONNECTING ROD INSPECTION
1. Inspect the small end and big end of connecting rod
(and matching rod cap) for damage, galling of
surface or pitting.
2. Measure small end I. D. in two directions as shown.
Record measurements and compare to
specifications. Replace connecting rod if worn past
the service limit specification.
MEASUREMENT
Connecting Rod Small End I.D.:
0.7879" - 0.7884" (20.015 - 20.025 mm)
Service Limit: 0.7897" (20.06 mm)
3. Install matching rod cap on connecting rod (without
bearings) and install the bolts.
4. Tighten bolts by hand, then torque to specification
prior to taking any measurements.
TORQUE
Connecting Rod Bolts:
Step 1: 9 ft-lb (12 Nm)
Step 2: 22 ft-lb (30 Nm)
Step 3: Tighten add’n 90°
ENGINE / COOLING SYSTEM
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