3
9926816 R07 - 2014-2016 RZR XP 1000 / XP4 1000 Service Manual
© Copyright Polaris Industries Inc.
3.61
PISTON RING INSTALLED GAP (1000)
1. Place each piston ring
q
inside the cylinder
w
. Use
the piston to push the ring squarely into cylinder, as
shown below.
2. Measure installed gap with a feeler gauge
e
at both
the top and bottom of the cylinder.
NOTE
A difference between top and bottom end gap
measurements is a general indication of cylinder taper
(wear). The cylinder should be measured for taper and
out of round.
3. If the installed gap measurement exceeds the
service limit, replace the rings.
MEASUREMENT
Piston Ring Installed Gap:
Top Ring: .010 - .014" (0.25 - 0.35 mm)
Service Limit: 1.6118 - 1.6122" (40.942 - 40.950 mm)
Second Ring: 1.6118 - 1.6122" (40.942 - 40.950 mm)
Service Limit: .028" (0.70 mm)
Oil Control Rails: .008 - .028" (0.20 - 0.70 mm)
Service Limit: .0354" (0.9 mm)
NOTE
Always check piston ring installed gap when installing
new rings and/or a new cylinder.
PISTON-TO-CYLINDER CLEARANCE
Measure piston outside diameter at a point 10 mm
q
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, page
3.57“Cylinder Inspection” procedure.
MEASUREMENT
Piston O.D. (Standard):
3.6597 ± .0003" (92.959 ± 0.008 mm)
Piston to Cylinder Clearance:
.0009 - .0019" (0.025 - 0.050 mm)
CONNECTING ROD INSPECTION
1. The 3 digit numbers stamped onto the intake side of
the connecting rod are serial numbers used to match
the rod cap
w
with the rod stem
e
.
ENGINE / COOLING SYSTEM
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