Cylinder / Piston Removal; Cylinder Inspection - Polaris 2015 RZR 900 Service Manual

Cylinder / Piston Removal

CAUTION
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.
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

Cylinder Inspection

1. Lay a straight edge across the top surface of the
2. Inspect cylinder for wear, scratches, or damage.
9925723 R01 - 2015 RZR 900 Service Manual
© Copyright 2014 Polaris Industries Inc.
ENGINE / COOLING SYSTEM
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 at several different points
warp by inserting a feeler gauge between the straight
edge and the cylinder surface. If warp exceeds the
service limit, replace the cylinder.
Cylinder Warp Limit:
.002" (0.05 mm)
NOTE: DO NOT hone the cylinders or attempt to
repair a damaged cylinder by honing.
3
and measure
1
3.55