3.54
ENGINE / COOLING
9924096 - 2013 RANGER RZR XP 900 / RZR XP 4 900 Service Manual
© Copyright 2012 Polaris Sales Inc.
IMPORTANT: DO NOT hone the cylinders or attempt
to repair a damaged cylinder by honing.
3. Inspect cylinder for taper and out of round with a dial
bore gauge. Measure in two different directions (front
to back and side to side), on three levels (0.59 in.
down from top, the middle, and 1.54 in. up from
bottom). Record measurements. If cylinder is tapered
or out of round beyond 0.001", the cylinder must be
replaced.
Piston Disassembly / Inspection
NOTE: New pistons are directional (intake vs.
exhaust), but can be placed in either cylinder.
1. Note location of the piston circlip gap (A) 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.
Cylinder Taper:
Service Limit: 0.001" (.025 mm)
Cylinder Out of Round:
Service Limit: 0.001" (.025 mm)
Standard Bore Size:
3.6614" ± .0003" (93 mm ± .008 mm)
0.59 in. (15 mm) Down From Top
1.54 in. (39.3 mm) Up From Bottom
DO NOT apply heat to piston rings or a loss of
radial tension could result.
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