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Cylinder Inspection - Polaris RZR XP 1000 Service Manual

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Cylinder Inspection

1. Lay a straight edge
cylinder at several different points and measure 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:
0.002" (0.05 mm)
2. Inspect cylinder for wear, scratches, or damage.
NOTE: DO NOT hone the cylinders or attempt to
repair a damaged cylinder by honing.
9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual
across the top surface of the
© Copyright 2014 Polaris Industries Inc.
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.
Cylinder Taper:
0.001" (0.025 mm)
Cylinder Out of Round:
0.001" (0.025 mm)
Standard Bore Size:
3.6614 ± 0.0003" (93 mm ± 0.008 mm)


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