Piston Ring Installed Gap; Starter Drive Bendix Removal / Inspection - Polaris RZR 800 2013 Manual

ENGINE

Piston Ring Installed Gap

1. Place each piston ring (A) inside cylinder (B) using a
piston to push ring squarely into place as shown.
Piston Ring Installed Gap:
See "800 EFI Engine Service Specifications", page
NOTE: Ring should be installed with the mark
facing upward.
2. Measure installed gap with a feeler gauge (C) at both
the top and bottom of the cylinder.
IMPORTANT: A difference in end gap indicates
cylinder taper. The cylinder should be measured
for excessive taper and out of round.
3. If the bottom installed gap measurement exceeds the
service limit, replace the rings. If ring gap is smaller
than the specified limit, file ring ends until gap is
within specified range.
NOTE: Always check piston ring installed gap
after re-boring a cylinder or when installing new
rings. A re-bored cylinder should always be
scrubbed thoroughly with hot soapy water,
rinsed, and dried completely. Wipe cylinder bore
with oil immediately to remove residue and
prevent rust.

Starter Drive Bendix Removal / Inspection

1. Remove stator housing bolts and remove housing.
2. Remove the flywheel nut and washer. Install
Flywheel Puller (PN 2871043) and remove flywheel.
NOTE: Do not thread the puller bolts into the
flywheel more than 1/4" or stator coils may be
damaged.
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3.9
9924707 - 2013–2014 RZR 800 Service Manual
© Copyright 2013 Polaris Sales Inc.
3. Remove starter bendix assembly (A). Note the thrust
washers located on both sides of the bendix.
4. Inspect the thrust washer for wear or damage and
replace if necessary.
5. After the bendix is removed, remove the two bolts
retaining the starter. Tap on the starter assembly (B)
with a soft faced mallet to loosen the starter from the
crankcase.
6. Inspect gear teeth on starter drive. Replace starter
drive if gear teeth are cracked, worn, or broken.