Piston-To-Cylinder Clearance; Connecting Rod Inspection - Polaris 2015 RZR 900 Service Manual

Piston-to-Cylinder Clearance

Measure piston outside diameter at a point 13 mm 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" procedure.
Piston O.D. (Standard):
3.6592 ± .0003" (92.950 ± .008 mm)
Piston to Cylinder Clearance:
.0014 - .0026" (.035 - .065 mm)

Connecting Rod Inspection

1. Inspect the small end and big end of connecting rod
2. Measure small end I. D. in two directions as shown.
3. Install matching rod cap on connecting rod (without
4. Tighten bolts by hand, then torque to Step 1: 9 ft-lb
9925723 R01 - 2015 RZR 900 Service Manual
© Copyright 2014 Polaris Industries Inc.
ENGINE / COOLING SYSTEM
(and matching rod cap) for damage, galling of
surface or pitting.
Record measurements
specifications. Replace connecting rod if worn past
the service limit specification.
Connecting Rod Small End I.D.:
0.7879" - 0.7884" (20.015 - 20.025 mm)
Service Limit: 0.7897" (20.06 mm)
bearings) and install the bolts.
(12 Nm)
Step 2: 22 ft-lb (30 Nm)
Step 3: Tighten add'n 90° prior to taking any
measurements.
and compare to
3
3.59