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Piston Ring Installed Gap; Piston-To-Cylinder Clearance - Polaris RZR XP 1000 Service Manual

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Piston Ring Installed Gap

1. Place each piston ring
the piston to push the ring squarely into cylinder, as
shown below.
2. Measure installed gap with a feeler gauge
the top and bottom of the cylinder.
NOTE: A difference between top and bottom end
gap measurements is a general indication of
cylinder taper (wear). The cylinder should be
measured for taper and out of round.
3. If the installed gap measurement exceeds the
service limit, replace the rings.
Piston Ring Installed Gap:
Top Ring: 0.010 - 0.014" (0.25 - 0.35 mm)
Service Limit: 1.6118 - 1.6122" (40.942 - 40.950 mm)
Second Ring: 1.6118 - 1.6122" (40.942 - 40.950 mm)
Service Limit: 0.028" (0.70 mm)
Oil Control Rails: 0.008 - 0.028" (0.20 - 0.70 mm)
Service Limit: 0.0354" (0.9 mm)
NOTE: Always check piston ring installed gap
when installing new rings and/or a new cylinder.
9925724 R01 - 2014-2015 RZR XP 1000 / RZR XP4 1000 Service Manual
inside the cylinder
. Use
1
at both
© Copyright 2014 Polaris Industries Inc.
ENGINE / COOLING SYSTEM

Piston-to-Cylinder Clearance

Measure piston outside diameter at a point 10 mm
from the bottom of the piston, at a right angle to piston
pin bore.
Subtract measurement from maximum measurement
obtained in Step 4 of
3.55"Cylinder Inspection" procedure.
Piston O.D. (Standard):
3.6597 ± 0.0003" (92.959 ± 0.008 mm)
Piston to Cylinder Clearance:
0.0009 - 0.0019" (0.025 - 0.050 mm)
up
1
Cylinder Inspection, page
3.59
3

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Rzr xp4 1000