3.53
ENGINE / COOLING
3
9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual
© Copyright 2012 Polaris Sales Inc.
Cylinder / Piston Removal
1. Perform “ENGINE DISASSEMBLY / INSPECTION -
TOP END” and the “ENGINE DISASSEMBLY /
INSPECTION - LOWER END” procedures.
2. Rotate the engine so the cylinder is facing up.
3. Remove the Cylinder Holding & Camshaft Timing
Plate (PU-50563) from the cylinder.
4. Carefully lift the cylinder and pistons from the upper
crankcase.
5. Remove the piston / connecting rod assemblies from
the cylinder.
NOTE: If the pistons are to be reused, mark the
pistons so they are reassembled in the same
cylinder bore and direction from which they were
removed (MAG / PTO).
Cylinder Inspection
1. Lay a straight edge (E) 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.
2. Inspect cylinder for wear, scratches, or damage.
Pistons must be removed from the cylinders
with the connecting rods attached.
DO NOT attempt to service the cylinder or
pistons without disassembling the crankcase.
Although you can remove the cylinder and
pistons without disassembly, you will not be able
to reassemble the engine because of the unique
cylinder skirt and crankcase design.
Cylinder Warp Limit:
.002" (0.05 mm)
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