Upper Crankcase Preparation; Piston Ring Installation - Polaris 2015 RZR 900 Service Manual

Bearing Selection Chart - Main Bearings
CRANKSHAFT
Code B
1 Blue
Case
Blue
2
3 Green

Upper Crankcase Preparation

NOTE: Always replace plain bearings when the
crankcase or connecting
disassembled. Refer to
procedures.
1. Remove all traces of crankcase sealer from the
crankcase mating surfaces. Inspect the surfaces
closely for nicks, burrs or damage.
2. Clean bolt hole threads to remove any oil or
crankcase sealant.
3. Inspect crankcase bearing bores. Replace the
crankcase assembly if a bearing bore is galled or if
bearing inserts have rotated in the case.
4. Be sure alignment pins are in place where used.
5. Refer to "Oil Flow Chart" at the beginning of this
chapter and trace the oil paths through the
crankcase and cylinder.
6. Flush all oil passages with solvent and then warm
soapy water. Rinse with clear, warm water and dry
with compressed air.
7. Be sure passages are clean and dry before
assembling the upper crankcase.

Piston Ring Installation

NOTE: Apply clean engine oil to all ring surfaces
and ring lands upon installation. Always check
G Y
piston ring installed gap before rings are installed on
piston (see Chapter 3 – Piston Ring Installed Gap,
Blue Green
page 3.58. Clean accumulated carbon from piston
Green Yellow
ring grooves and oil ring lube holes if piston has
been in service.
Yellow Yellow
rods have been
bearing selection
1
1. Place oil control ring expander in oil ring groove.
2. Install lower rail with end gap positioned on the
3. Install upper rail with end gap positioned on the
9925723 R01 - 2015 RZR 900 Service Manual
© Copyright 2014 Polaris Industries Inc.
ENGINE / COOLING SYSTEM
Top Ring Spring Expander
Second Ring Lower Rail
Upper Rail
Rotate expander in groove until butt ends are on
PTO side of piston .
NOTE: Ends must butt squarely together and
must not overlap.
intake side of piston .
exhaust side of piston .
3
3.63