Piston Removal; Cylinder Inspection - Polaris RZR 170 2009 Service Manual

Piston Removal

1. Remove circlip from either side of piston.
2. Push piston pin out of piston. If necessary, heat the crown
of the piston slightly with a propane torch. CAUTION: Do
not apply heat to the piston rings. The rings may lose radial
tension.
3. Remove the compression rings, starting with the top ring.
* Using a piston ring pliers: Carefully expand ring and lift it off
the piston. CAUTION: Do not expand the ring more than the
amount necessary to remove it from the piston, or the ring may
break.
* By hand: Placing both thumbs as shown, spread the ring open
and push up on the opposite side. Use care to not scratch the ring
lands.
4. Repeat procedure for second ring.
5. The oil control ring is a three piece design consisting of a
top and bottom steel rail and a center expander section.
Remove the top rail first followed by the bottom rail and
expander.

Cylinder Inspection

1. Remove all gasket material from the cylinder sealing
surfaces.
2. Inspect the top of the cylinder for warpage using a straight
edge and feeler gauge.
Cylinder Warp:
.002" (.05 mm) MAX
3. Inspect cylinder for wear, scratches, or damage.
4. Inspect cylinder for taper and out of round with a
telescoping gauge or a dial bore gauge. Measure in two
different directions, front to back and side to side, on three
different levels (1/2" down from top, in the middle, and
1/2" up from the bottom).
1/2" Down From Top of Cylinder
X
X
X
1/2" Up From Bottom
ENGINE
= In. / mm.
Y
Y
Y
3.23
3