Cylinder Inspection - Polaris RZR PRO XP 2020 Service Manual

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5. Carefully lift the cylinder and pistons from the upper

6. Remove the piston / connecting rod assemblies from

the cylinder.

If the pistons are to be reused, mark the pistons so they

are reassembled in the same cylinder bore and

direction from which they were removed (MAG / PTO).

9850068 R01 - 2020-2021 RZR PRO XP / XP 4 Service Manual

ENGINE / COOLING SYSTEM

CYLINDER INSPECTION

1. Lay a straight edge across the top surface of the

cylinder at several different points

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:

.002" (0.05 mm)

2. Inspect cylinder for wear, scratches, or damage.

DO NOT hone the cylinders or attempt to repair a

damaged cylinder by honing.

3. Inspect taper and out of round with a dial bore gauge.

4. 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 (0.6" down

from top, the middle, and 1.5" up from bottom).

Record measurements. If cylinder is tapered or out of

round beyond the service limit, the cylinder must be

Standard Bore Size:

3.6614 ± .0003" (93 mm ± 0.008 mm)

Cylinder Taper:

Service Limit: .001" (0.025 mm)

Cylinder Out of Round:

Service Limit: .001" (0.025 mm)

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